Sweco Primax Trailer Manual 18-04

PRIMAX Falling Weight Deflectometer
Trailer-mounted
User Manual
PRIMAX trailer version

Instrument Manual
Instructions for PRIMAX 7-150 kN, 7-250 kN, 7-350 kN

USER MANUAL PRIMAX FWD/HWD/SHWD – trailer-mounted
Contents
Preface ................................................................................................................................................................... 7
I. Condition of use ............................................................................................................................................ 8
Part 0: Safety ........................................................................................................................................................ 9

0.1 Safety Alert Symbols ............................................................................................................................. 9
0.2 Responsibilities of equipment owner................................................................................................. 10
0.2.1 Safety information ....................................................................................................................... 10
0.2.2 Instructions, requirements, and standards .............................................................................. 10
0.2.3 User qualifications ...................................................................................................................... 10
0.3 Safety Practices ................................................................................................................................... 11
0.3.1 Intended use of equipment ........................................................................................................ 11
0.3.2 Instructions and safety messages ............................................................................................ 11
0.3.3 Installation practices ................................................................................................................... 11
0.3.5 Maintenance and repair practices ............................................................................................ 12
0.4 Other safety precautions ..................................................................................................................... 13
Part 1: Introduction ......................................................................................................................................... 14

1.1 Sweco Danmark Pavement Consultants .......................................................................................... 14
1.1.1 CE marking ........................................................................................................................................ 14
1.2 General Description ............................................................................................................................. 15
1.2.1 The principle ...................................................................................................................................... 15
1.2.2 The measuring procedure ............................................................................................................... 16
1.2.3 Measuring cycle ................................................................................................................................ 16
1.2.4 Where would FWD measurements be of advantage .................................................................. 16
Part 2: Technical Specifications ................................................................................................................... 17

2.1 Trailer Version ...................................................................................................................................... 17
2.2 Data Acquisition System ..................................................................................................................... 19
2.3 System................................................................................................................................................... 20
2.4 Geophone signal .................................................................................................................................. 21
Part 3: Hardware manual .............................................................................................................................. 22

3.1 General information on trailer ............................................................................................................ 22
3.2 Warning lights ....................................................................................................................................... 24
Part 4: System Powering ............................................................................................................................... 25

4.1 System Powering ................................................................................................................................. 25
4.2 Battery (2 x 12VDC) ............................................................................................................................ 27
4.3 Honda Engine ........................................................................................................................................... 27
4.4 Power Inverter ...................................................................................................................................... 29
Part 5: Information on Hydraulic system ..................................................................................................... 30

5.1 Hydraulic System ................................................................................................................................. 30
5.2 Hydraulic Drawing ................................................................................................................................ 31
5.3 Hydraulic Pump .................................................................................................................................... 32
5.3.1 Hand Pump and Emergency Operation .................................................................................. 33
5.4 Oil filter .................................................................................................................................................. 33
5.5 Hydraulic Cylinder ................................................................................................................................ 33
5.6 Hydraulic Valve .................................................................................................................................... 35
5.7 Hydraulic Pressure Switch.................................................................................................................. 36
5.8 Cable for Beam .................................................................................................................................... 36
Part 6: Electrical system ................................................................................................................................ 37
Page 2 Sweco Danmark A/S, Pavement Consultants

6.1 Electrical System ................................................................................................................................. 37
Part 7: Non-contact Switch ........................................................................................................................... 38

F2: Magnet is down .................................................................................................................................... 39
F3: Release lock (lower switch)................................................................................................................ 40
F5: Lock 1 is on .......................................................................................................................................... 40
F6: Beam is up ............................................................................................................................................ 40
F7: Lock 2 is on .......................................................................................................................................... 41
F8: Foot is up (upper switch) .................................................................................................................... 41
F9: Weight is down ..................................................................................................................................... 41
F10: Manual temperature in holder .......................................................................................................... 42
F11 (F25) and F12 ..................................................................................................................................... 42
F13 and F14 ................................................................................................................................................ 42
Part 8: Height Transducers ........................................................................................................................... 43
Part 9: Pressure Switch ................................................................................................................................. 43
Part 10: Relay ................................................................................................................................................. 43

10.1 Relays K1-K10 ................................................................................................................................... 44
10.2 Relay K21 for hydraulic motor ......................................................................................................... 44
10.3 Main relay ........................................................................................................................................... 44
Part 11: Fuses ................................................................................................................................................. 45

11.1 Main fuse ............................................................................................................................................ 45
11.2 Fuses Box A ....................................................................................................................................... 47
Part 12: Load Cell and Geophones ............................................................................................................. 48

12.1 Load Cell ............................................................................................................................................. 48
12.2 Seismic Geophone ............................................................................................................................ 49
Part 13: Temperature Sensor ....................................................................................................................... 49

13.1 Air temperature: ................................................................................................................................. 50
13.2 Surface temperature: ........................................................................................................................ 50
13.3 Manual temperature sensor: ............................................................................................................ 50
Part 14: SBC SYSTEM .................................................................................................................................. 51

14.1 SBC System (Single Board Computer) Software ......................................................................... 51
14.2 A/D-card .............................................................................................................................................. 53
14.3 Digital I/O card ................................................................................................................................... 53
Part 15: Preparing/Checking the FWD before Measurements ................................................................ 54

15.1 Vehicle................................................................................................................................................. 54
15.2 FWD Mechanics/Hydraulics ............................................................................................................. 55
15.3 Check the FWD in manual mode .................................................................................................... 56
Part 16: Setup for Weight/Buffer .................................................................................................................. 57

16.1 Setup for Buffer .................................................................................................................................. 57
16.2 Setup for Weight ................................................................................................................................ 60
16.3 Target Load and load time: .............................................................................................................. 61
16.4 Setup of geophones .......................................................................................................................... 66
Part 17: Trouble shooting .............................................................................................................................. 67

17.1 CONTENTS ........................................................................................................................................ 67
Sweco Danmark A/S, Pavement Consultants Page 3

17.2 Car - troubleshooting......................................................................................................................... 69
17.3 Foot arrangement - troubleshooting ............................................................................................... 70
17.4 Foot arrangement - troubleshooting ............................................................................................... 71
17.5 Weight arrangement - troubleshooting ........................................................................................... 72
17.6 Power supply unit - troubleshooting ................................................................................................ 73
17.7 Power supply unit – troubleshooting ............................................................................................... 74
17.8 Computer equipment – troubleshooting (including printer, etc.) ................................................. 75
17.9 Data reading – troubleshooting - Temperature sensor ................................................................ 76
17.10 Chainage counter - troubleshooting ............................................................................................. 77
17.11 Data reading - troubleshooting ...................................................................................................... 78
17.12 Marking equipment – troubleshooting .......................................................................................... 79
Part 18: Service and maintenance ............................................................................................................... 80

18.1 Car ....................................................................................................................................................... 80
18.2 Load Plate Arrangement ................................................................................................................... 81
18.3 Falling Weight Arrangement ............................................................................................................ 82
18.4 Control Unit ......................................................................................................................................... 83
18.5 Power Supply Unit ...................................................................................................................... 84
18.6 Recording Equipment ....................................................................................................................... 85
18.7 Computer Equipment ........................................................................................................................ 86
APPENDIX 1 Mechanical drawings ............................................................................................................. 87

1.1 Main cylinder and magnet .................................................................................................................. 87
1.2 Foot system .......................................................................................................................................... 88
1.3 Base weight ........................................................................................................................................... 89
1.4 Lock System ......................................................................................................................................... 90
1.5 Buffer system ........................................................................................................................................ 91
1.6 Main unit ................................................................................................................................................ 92
1.7 Main unit - detail ................................................................................................................................... 93
1.8 Main unit - detail ................................................................................................................................... 94
1.9 Foot system .......................................................................................................................................... 95
1.10 Base weight ........................................................................................................................................ 96
1.11 Lock system........................................................................................................................................ 97
1.12 Guidance Bars ................................................................................................................................... 98
1.13 Magnet and main cylinder ................................................................................................................ 99
1.14 Main magnet ..................................................................................................................................... 100

DOCUMENT CHANGE RECORD

Issue Date Changes Approved
(e.g. change notes, amendments, software function change)
1 Oct. 2008 First issue of revised manual René Clemen
2 Sep. 2009 Second issue of revised manual John Kern
3 Oct. 2014 Third issue of revised manual Michael Henriksen
4 Jan. 2016 Fourth issue of revised manual Henny Schøler
5 April 2018 Fifth issue of revised manual Michael Henriksen
We have reedited our manual for PRIMAX FWD/HWD/SHWD. We are still working on the manual and any good
ideas you may have to improve our manual are most welcome.

User manual: PRIMAX FWD 1.00
© Sweco Danmark A/S, Pavement Consultants, Kokbjerg 5, DK-6000 Kolding
This edition was first published in 2009
All rights reserved; no part of this publication may be

reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written permission of the Publishers.
The English version of the PRIMAX FWD user manual is the only authorised manual. Any other
translations of this manual are not valid and Sweco Danmark A/S cannot be held responsible for the
contents of such manuals.
Printed in Denmark by Sweco Danmark A/S

Preface
This manual has been written to be the best of our knowledge and is intended to introduce
users to proper use and maintenance of this equipment and we recommend to read the
manual and the safety sections and condition of use before taking this equipment into use
and to follow the training courses which are always offered in connection with delivery of our
equipment.
We believe this manual to be correct at the time of publishing. Still Sweco exclude all liability
for loss (whether arising under contract, tort, statute, or otherwise, to the extent lawful,
arising from the contents of the manual or from its use.
Liabilities, which cannot be excluded, is reduced to the full extent lawful.
Although Sweco is aware of its liabilities and always will comply with such provisions, we
expect people to apply their own skill and judgement when using the information contained in
the manual and when using the equipment.

I. Condition of use
Intellectual Property:
Software described in this manual is the property of Sweco Danmark A/S, Pavement
Consultants (hereinafter called Sweco). The software is protected by copyright laws and
international copyright and other intellectual property laws and treaties. The software and all
information embodied in the software is confidential.
Disclaimer:
Sweco disclaims any express or implied warranties of merchantability, title or fitness for a
particular purpose. Distribution of any of Sweco’s software is forbidden without to express
written consent of Sweco. Furthermore, Sweco reserves the right to discontinue distribution
of any Sweco software.
Warranty:
Sweco shall determine whether or not any defective item shall be repaired or replaced, within
the warranty period and in accordance with the issued warranty certificate.
Software upgrades do not extend or modify the warranty on the equipment already provided.
Subject to the provisions in this section, Sweco warrants that:
1. The software will perform in accordance with the written materials for a period of 12
months from date of the warranty certificate
2. Hardware will be free from defects in material and workmanship for a period of 12 months
from date of the warranty certificate provided that service and maintenance is performed
in accordance with the user instructions and under normal use.
Customer remedies:
Sweco’s liability under contract, tort, equity, breach of statutory duty or any other law,
regulation or rule and your exclusive remedy in respect of any rights accrued to you and your
successors in title and permitted assigns against Sweco, its employees pursuant of any of
the foregoing arising from your use of the equipment and software shall be repair or
replacement of the software or hardware that does not meet Sweco’s limited warranty (as
described above) and which is returned to Sweco with your purchase documents within the
warranty period.
No other warranties:
Sweco disclaims to the extent permitted by law, all other warranties, either express or
implied, including but not limited to warranties of merchantability and fitness for a particular
purpose, with respect to the product, the accompanying written materials or the accessories
supplied.
No liability for consequential damages:

The employees of Sweco shall under no circumstances be liable for any damages
whatsoever (including but not limited to, damages for loss of business profits, business
interruption, loss of business information, or other pecuniary loss) arising out of the use or
inability to use the equipment or associated data.

Part 0: Safety
Read this section before using the equipment. This section contains recommendations and
practices which should be observed to ensure safe installation, operation and maintenance
(hereinafter referred to as “use”) of the equipment described in this manual.
You will find additional safety information such as task-specific safety alert messages
appearing as appropriate throughout the manual.
WARNING: Failure to follow the safety messages, recommendations, and hazard avoidance
procedures in this manual can result in personal injury, including death or damage to
equipment or property.
0.1 Safety Alert Symbols
Below safety alert symbols and signal words are used throughout the manual to alert the
reader to personal safety hazards or to identify conditions that may result in damage to
equipment or property. Comply with all safety information in this manual and the safety
information that follows the signal word.
Warning: Indicates a potentially hazardous situation that can result in serious personal
injury, including death if not avoided.
Caution: Indicates a potentially hazardous situation that can result in minor or moderate
personal injury, if not avoided.
Caution and warning: Sign on Generator, to be observed if a generator is mounted on

your FWD equipment
Warning: Danger Moving Machinery – this sign indicates a potentially hazardous
situation which can result in serious personal injury.
Caution: Emergency button which is placed on FWD trailer frame and on side of cabinet
with hydraulic system
Caution: Used without the safety alert symbol: Indicates a potentially hazardous situation
that can result in damage to equipment or property, if not avoided.
Warning: Indicates a potentially hazardous situation that can result in serious personal
injury.

0.2 Responsibilities of equipment owner
Equipment owners are responsible for managing safety information, insuring that all
instructions and regulatory requirements for use of the equipment are met, and for qualifying
all potential users.
0.2.1 Safety information
Research and evaluate safety information from all applicable sources, including owner-
specific safety policy, best industry practices, governing regulations, and this manual.
Make safety information available to equipment users in accordance with governing

regulations. Contact the authority having jurisdiction for information.
Maintain safety information, including the safety labels affixed to the equipment, in readable
condition.
0.2.2 Instructions, requirements, and standards
Ensure that the equipment is used in accordance with the instructions and information
provided in this manual, governing codes and regulations, and best industry practices.
If applicable, receive approval from you facility’s engineering or safety department, or other
similar function within your organization, before installing or operating the equipment for the
first time.
Provide appropriate emergency and first aid equipment.
Conduct safety inspections to ensure required practices are being followed.
Re-evaluate safety practices and procedures whenever changes are made to the process or
equipment.
0.2.3 User qualifications
Owners of equipment are obliged to ensure that users:
• Receive safety training appropriate to their function and in accordance with governing
regulations and best industry practices.
• Are familiar with the equipment owner’s safety and accident prevention policies and
procedures
• Receive equipment- and task-specific training from another qualified individual.
• Possess industry- and trade-specific skills and a level of experience appropriate to their
job functions
• Are physically capable of performing their job function and are not under the influence of
any substance that degrades their mental capacity or physical capabilities.
NOTE: Sweco can provide equipment-specific installation, operation and maintenance training.
Contact your Sweco representative or Sweco directly for more information.

0.3 Safety Practices
The safety practices apply to the use of the equipment in the way described in the present
document. The information represents the best safety practices for equipment of similar
hazard potential used in similar industries and is not meant to include all possible safety
practices.
0.3.1 Intended use of equipment
• Use the equipment only for the purposes described and within the limits specified in this
manual.
• Do not modify the equipment
• Do not use unapproved auxiliary devices. Contact your Sweco representative if you have
questions on the use of non-standard auxiliary devices.
0.3.2 Instructions and safety messages
• Read and follow the instructions of this manual and other referenced documents.
• Familiarise yourself with the location and meaning of the safety warning labels and tags
affixed to the equipment, and appearing from the control software and data collection
software. Refer to Safety Labels and Tags (if available) at the end of this part.
• If you are unsure of how to use the equipment, please contact your Sweco representative
or Sweco directly for assistance.
0.3.3 Installation practices
• Install the equipment in accordance with the instructions provided in this manual and in
the documentation provided with auxiliary devices.
• If the required installation configuration does not match the installation instructions,
please contact your Sweco representative.
• Trailer hitch – ball must match coupler to ensure correct towing of equipment and prevent
that the trailer is disconnected from towing vehicle while driving.
• Loading of towing vehicle – do not stow too much cargo in rear of car. This will tilt trailer
frame and course unstable driving on the road.
• Do not pass communicable through a back door. This may damage the cable.
• Too low voltage may cause overheating and breakdown of FWD unit
• Check Plate-low alarm connection
• Park/alarm override plug, do not use this in the field, only for servicing purposes

• Place computer conveniently for operator
• Do not cover ventilation grids of computer
• Maximum temperature limit for computer is typically 40oC if placed in shade. Storage
temperature is -40oC to +65oC. Remove computer from vehicle after use to protect it from
high humidity and large temperature shifts from day to night.
• Warning signs on trailer: check local requirements with regard to warning signs on FWD
trailer. Consult authorities if required.
0.3.4 Operating Practices
• Familiarise yourself with the location and operation of all safety devices and indicators.
• Make sure that the equipment, including safety devices, is in good working order.
• Do not use equipment that is malfunctioning or shows signs of potential malfunction.
0.3.5 Maintenance and repair practices
• Perform scheduled maintenance and calibration activities at the intervals described in this
manual.
• Use only new or factory-authorised refurbished replacement parts.
• Read and comply with the manufacturer’s instructions and any MSDS supplied with the
equipment.
• Check that all safety devices are operating correctly prior to using the equipment.
• Keep equipment safety warning labels clean and replace any worn or damaged labels.

0.4 Other safety precautions
Below you find some important safety precautions which must be observed when operating
the Falling Weight deflectometer for your own safety and for the safety of others. Always
keep in mind that a Falling Weight deflectometer can cause injury to persons in case of
malfunction, wrong handling or mistreatment. All safety warnings in this manual must be
observed.
When operating the equipment:

• Stay clear of all moving parts and do not allow other persons to stand close to the FWD
while operating
• Do not place loose objects such as tools on or near the falling weight arrangement while
measuring
• Do not leave the weight when raised to top-position
• Do not leave sub-assembly raised and unlocked
• Make sure that warning lights are working and not damaged
• Make sure that cables are not squished or damaged
• Never place hands or feet under drop weight
• Turn of power if persons are close to moving parts
• When leaving a measuring point – see to it that foot and geophones are in transport
position.
When maintaining the equipment:

• Support the weight or sub-assembly during maintenance
• When adjusting hydraulic pressure: If the pressure exceeds 120 bar, the hydraulic
system may be severely damaged
• Do not push the valves with a sharp tool – this would damage the valves
• Magnet switch: The falling weight must be in safety position when changing or adjusting
this switch!
• Whenever persons are close to moving parts of the FWD/HWD system, turn off al power
• Never place hands under drop weight when not supported
When demonstrating the equipment or training persons, etc.:

• Be aware of where other persons are place when operating the equipment
• Always announce what you are doing prior to activating equipment or pressing any
control button
Freight handling:
• When pulling the FWD trailer with a vehicle; make sure that hitch ball match coupler
• Do not carry too much cargo in towing vehicle; may cause the trailer frame to tilt and
results in unstable driving on the roads
• Warning lights and placing to comply with local legislation and regulations
• Do not start driving with foot down – emergency switch will send an alarm to driver
• When transporting FWD trailer by sea or air: make sure no fork lifts or cranes are used
for handling the equipment and disconnect and protect batteries from short circuit.

Part 1: Introduction
1.1 Sweco Denmark Pavement Consultants
Behind the PRIMAX falling weight deflectometers are more than 75 years of experience in
road construction and road maintenance.
Sweco Danmark Pavement Consultants specialises in road surfacing maintenance. We see

as our main task the optimisation and improvement of the ways in which society channels its
resources in extending and maintaining road networks, airports and other such enterprises.
In 1968, Sweco Danmark Pavement Consultants began developing and manufacturing falling
weight deflectometers (FWD). The latest model is PRIMAX, a precise and very effective
FWD, and a combination of several years of experience and customer requirements.
PRIMAX is modular in design and can be upgraded within the load ranges 7-150 kN, 7-250
kN or 7-350 kN for use on road and airfield pavements the latter especially for runways,
taxiways, aprons, etc. that must be capable of withstanding Boeing 747, Airbus380 and other
large aircrafts.
The module principle means that there is no need to invest in new FWD equipment. Instead,
all that is necessary is to add more geophones, time history, larger load cells, more weights.
The trailer-mounted equipment can also be built into a van, without having to invest in new
basic measuring equipment. PRIMAX offers infinite possibilities.
1.1.1 CE marking
The PRIMAX FWD test system carries a CE mark in accordance with the EU Machine and
EMC Directives. The falling weight deflectometer thus fully complies with the safety
requirements laid down for work with measuring equipment. We refer to the appendix for CE
certificate.

1.2 General Description
Road bearing capacity measurements can be carried out with several kinds of equipment,
one of these being a Falling Weight Deflectometer (FWD). The FWD is the most commonly
used equipment for this kind of measurements.
When analysing and calculating the data collected with the FWD, it is possible to find
answers to various questions occurring when maintaining road networks e.g.:
• Dynamic E moduli
• Residual life
• Critical layers
• Reinforcement needs
1.2.1 The principle
The measuring principle is rather simple.
A set of weights is dropped onto a platform with springs (rubber buffers) and the impact load
is transferred to the pavement through a Load plate.
The load simulates the dynamic load from a truck.
Normally, the load applied on road pavements is 10-65 kN and on airfield pavements 65-350
kN.
When subjected to a load, the pavement will bend and a deflection basin is created. The
deflections at various distances from the loading centre are recorded by the sensors
(geophones) and stored in a data file.

1.2.2 The measuring procedure
Before starting up measuring, certain preparations must be done, such as adjustment of

geophone distances, checking that the sensors are measuring correctly for which purpose a
reference point is used.
Before starting up measuring, it is essential to check the geophone distances on the

geophone beam. This is very important, as the accuracy and results of the calculations and
analyses depend on the data collected.
The geophones are set at distances, which have been calculated to cover various kinds of
pavement structures that are normally measured with FWD.
1.2.3 Measuring cycle
A measuring cycle normally consists of 3 drops. One set drop and two measuring drops.
The set drop adjusts the FWD. The two other drops are measuring drops. The latter are
compared with each other and the maximum allowable reference values in the data
collection software. If the difference is larger than the set allowable difference, a new
measurement should be made. This cycle consists of two drops and if the measured result is
accepted then the result is stored, and the operator may go on to the next measuring point.
1.2.4 Where would FWD measurements be of advantage?
In all cases where new overlays are considered.
In order to get a survey of the strength of a road network.

Part 2: Technical Specifications

2.1 Trailer Version
L x W x H (m) 4.30 x 1.84 x 1.30
(excl. of warning lights)
Weight 1230 kg (without weight)
Number of axles 2
Load Characteristics
Load range 7-150 kN (7-250 kN, 7-350 kN)
Load pulse duration 25-30 ms
Load pulse shape essentially half-sine
Load pulse rise time approx. 10-15 ms
Load Cell
Load cell accuracy 2% +/- 0.2 kN
Load resolution 0.01 kN (0.01 KPa)
Load plate 4-split, 300 mm in diameter
Deflector Sensor
Sensor type Seismic Velocity Transducer
Number of geophones 1-18 (optimum)
Geophone accuracy better than +/- 2%
Geophone resolution 0.1 micron
Geophone range 2200 micron
Geophone beam 2500 mm from centre
Temperature Sensor
Sensor type PT 100
Number of sensors 1 manual – optional 3
(surface, air, manual)
Temperature accuracy better than 1C
Temperature resolution 0.1 C
Optional IR-surface sensor

Temperature accuracy +/- 1.5C
Temperature resolution 0.1 C

Optional GPS/DGPS Antenna

GPS Baud rate 9600 baud
NMEA output format GGA, GSV, GSA, RMC
Garmin GPS18x PC
GPS accuracy 15 meter or better
Garmin GPS 19x HVS
(Using WAAS)
DGPS accuracy 3 meter or better
Garmin GPS 19x HVS
(with subscription)
DGPS accuracy Sub meters
Operation May be operated by one person

Temperature range (measurement) -20C to + 60 C (air temperature)
Temperature range (transport) -40 C to + 70 C
Safety Complies with EU regulations for

mechanical and electronic devices
(CE marking)
Power Supply (FWD)
Trailer version (option 1) 24 VDC generator unit mounted on
trailer.
Trailer version (option 2) 12 VDC from towing vehicle and
converted to 24VDC.
Trailer version (option 3) 24 VDC generator unit mounted on
towing vehicle.
Distance Meter Counter
Accuracy Better than +/- 1m
Integrated in data collection software

2.2 Data Acquisition System
• Time history (real time): On all geophones and load

• Simultaneous sampling (real time): All channels, load cell, temp. and geophones
• Resolution: 16 BIT on all channels (load, geophones, temperature, falling height)
• Sampling: 4 kHz per channel (optional up to 10kHz)
• Sampling period: 120ms
• Data storage: SQL Database
• Data storage (time history): SQL Database
Data Collection Software: System:

MS Windows Win7 and Win8
• Easy set-up of data and sequence using wizard

• Presentation of time history and peak value displayed simultaneously
• Automatic loading of temperature with alarm for correct measurement
• Full manual mode operation from PC
• Easy set-up of user layout with save and load functions
• Easy file handling module with view function
• Integrated distance meter calibration module
Optional Hard- and Software
• Paint/point marker
• Rear deflection extension beam (rear 600 mm & transverse 450 mm)
• Stacking tower tester (relative calibration procedure for geophones)
• 450mm load plate (optional rigid or 4 split)
• Video camera & monitor
• Warning light (trailer and car)
• National language versions (may require national MS Windows version)
• Calibration reference package (geophones) ready for operation: hardware &
software
• Upgrade to heavy weight deflectometer (250 kN) or super HWD (350 kN)
• New: PRIMAX Wireless connection (PC ↔ FWD unit)
• New: PRIMAX Pavement Road Image System
• New: PRIMAX Data Collection Software
• PRIMAX extended warranty
• 12/24Volt unit powered by the towing vehicle, portable for use with different
• Upgrading from trailer to built-in version (VW transporter van)
• Reflecting safety panel (traffic signs)
• Automated IR pavement surface temperature transmitter
• DGPS (antenna and software)

2.3 System
Normally, the Sweco PRIMAX FWD/HWD/Super HWD system consists of the

following:
Geo Load Temp. Height.

TOWING VEHICLE TRAILER
Serial printer.
FCU BOX
Serial printer cabel
CPU
Analog
220v ac power CPU-bus
supply Parallel com. cabel. I/O
Digital
Digital
Power Output
Computer.
Supply Digital
Sinus Wave 200W Input
12V dc
220v ac
12 Vdc 24 Vdc
Warning Warning
inverter
Trailer lights
Light. Hydraulic motor
Light.
Connection
M
Batt
12V
Original standard batteri
Honda gasoline motor
G 12V dc Batt Batt

G M
12V 12V 24V dc Alternator
Original standard alternator

2.4 Geophone signal
Geophone signal handling is the most sensitive part of the FWD PRIMAX system.
The reason is the fact that a geophone (velocity transducer) is not linear in the low
frequency band, approx. 0 Hz to approx. 7 Hz. Furthermore, each geophone has it own
“cut off frequency” which varies within the range of +/- 0.5 Hz. This means that in the
lower band each geophone can vary with up to 1 Hz (6.5-7.5 Hz). To compensate for
this non-linearity in the lower frequency band, a reverse filter with the same
characteristics is added. In this way a geophone linear from approx. 0 Hz to approx.
400 Hz is achieved.
If only a filter at 7 Hz is added, this may cause problems, as each geophone may vary
from 6.5-7.5 Hz. Therefore, it is essential to know the exact cut off frequency of each
geophone.
As a result of years of development, Sweco Pavement Consultants has found the

optimum solution to this problem. For each geophone, Sweco Pavement Consultants
finds the precise point where the compensation filter should be added. In this way, a
frequency characteristic, which is linear from 0 Hz is achieved. In addition to this
unique system, Sweco Pavement Consultants has developed a system in which the
amplification, filter compensation, signal integration are done in the software. The
advantage is that the system becomes much more stable compared to a hardware-
based systems (electronics), which is the most common system. The reason is the fact
that electronic components change values over time as opposed to software.

Part 3: Hardware manual

3.1 General information on trailer
The PRIMAX trailer is a double-axle trailer with overrun brake operating on all four
wheels. The trailer weight is approx. 1270 kg with one layer of weights (with 11 layers
approx. 1670 kg).
Make sure that the towing vehicle is allowed to tow the stated weight. Contact the
local authorities if necessary. The trailer is supplied with a 50 mm trailer hitch ball (EU
standard).
The hitch must be 450-475 mm above ground level allowing the trailer frame to be parallel with
the ground surface and the guide shaft for the drop weight to be perpendicular to the ground
It is important that the trailer frame is placed parallel with the ground surface as the
guide shaft for the foot must be perpendicular to the ground surface.
The trailer is equipped with the following as standard:
Tail light, left

Tail light, right
Tail light consists of:
Yellow turn light
Red running light
Red stop light
The towing vehicle must be of a suitable size and have enough driving power to tow a
trailer of approx. 1500 kg (1800 kg SHWD).
Sweco Danmark Pavement Consultants recommends an engine with automatic

transmission (because of many starts and stops) and capable of very low rpm
operation. The vehicle shall be mounted with a 50 mm diameter hitch ball (EU
standard), which shall be placed in a height of 450 mm above ground level.

DIN 72.577 Standard
The towing vehicle must comply with local authority regulations and the car
manufacturer’s specifications.
Trailer hitch with a 50 mm

diameter ball.
Towing vehicle
450 mm.

3.2 Warning lights
To warn the traffic during testing, a warning flasher is mounted as standard on top of
the FWD. Due to the height of the towing vehicle a warning flasher should also be
mounted on this for maximum visibility. Sweco Pavement Consultants recommend
consulting the local authorities concerning guidelines for warning light selection and
positioning.
During transport (e.g. air freight) dismantling of the warning flasher on the FWD is
possible in order to reduce the height of the FWD.
If warning lights other than those provided by Sweco Pavement Consultants are to be
mounted, these must be 24 VDC, max. 8 AMP.

Part 4: System Powering

4.1 System Powering
The FWD can be powered in three ways:
Trailer version (option 1) :24 VDC generator unit mounted on trailer.

Trailer version (option 2) :12 VDC from towing vehicle and converted to 24VDC.
Trailer version (option 3) :24 VDC generator unit mounted on towing vehicle.
All three options can run individually, or be combined e. g. as a backup solution.
24 VDC generator unit mounted on trailer (option 1).
An alternator (24 VDC) driven by the Honda petrol engine is charging the battery pack
(2 x 12 VDC battery connected in serial) on the trailer.
Generator
12 VDC from towing vehicle and converted to 24VDC (option 2)
It is possible to take out the 12VDC from the towing vehicle and connect the 12VC to a
12/24VDC converter mounted on the FWD trailer or the towing vehicle. The output from
the 12/24VDC converter should be approx. 40 amp. Another possibility is to connect
two 20 amp in parallel mode.

24 VDC generator unit mounted on towing vehicle (Option 3)
On most towing vehicles an extra 24VDC generator can be mounted to power the FWD via a
cable on the towing vehicle and connect it to the standard power connection plug at the front
end of the FWD trailer.

4.2 Battery (2 x 12VDC)
Battery pack
The battery pack (24 VDC) on the trailer powers the FWD control, measuring system and
warning lights (on the trailer). By means of the power front connector it is possible to receive
power from the towing vehicle if required (note: max 24 VDC).
The two 12VDC batteries are connected in series.
NB: If an external battery charger is applied, the two 12VDC batteries must be
simultaneously charged with a 24VDC charger connected in series.
Only apply a charger that stops charting automatically as soon as the battery has been fully
charged (100%). Otherwise the risk of damaging the battery is high.
When replacing a battery ALWAYS replace with a new battery with the below specifications:
• 12VDC
• min. 85AMP
• Battery type: Deep cycle
4.3 Honda Engine
NOTE:
Only run the generator/ Honda engine when the power
plug in front of the trailer is plugged in plug
The generator is driven by a 5.5 hp Honda engine.

The following points must be observed:
• Starter rope
• Engine on/off switch
• Fuel tank
• Choke on/off switch
• Gas engine rpm handle
• Air filter
• Oil level cap

When starting the engine:
1. Check the fuel (top up if necessary)

2. Check oil level (top up if necessary)
3. Set choke on
4. Set engine switch on
5. Pull hard in the starter rope
NOTE:
The engine MUST run at high RPM to make generator charge the battery.
When the engine is running, the choke can be put in off position.
When stopping the engine: Set the engine switch on/off in off position.
NOTE:
The oil level has to be at the brim of the hole. If the oil level is too low, the engine
will stop automatically. If any problems arise, please also check/see the original
instructions book for the Honda engine.

A good way of verifying, whether the power supply is

charging the batteries or not, is to note the position of the
voltmeter when the generator is not turned on and then note
whether it changes to a positive level when turning on the
generator.
4.4 Power Inverter
Normally, the power inverter 12 VDC/220 VAC is installed in and powered by the towing
vehicle. The power inverter is applied for powering computer and printer.
The power inverter should be of high quality – this means that the 220 VAC output must be a
clear sine curve and not a trapeze or squared curve.
Sweco Pavement Consultants recommends an inverter with the following minimum

specifications:
Output:
220-240 VAC
200 WATT
Clear sine curve
Power inverter

Part 5: Information on Hydraulic system

5.1 Hydraulic System
This part explains the functioning of the hydraulic system.
The hydraulics are applied for:
1) Lowering and raising foot and weight system

2) Lowering and raising weight system
3) Transport lock on/off
4) Emergency operation of the foot and weight system
Overleaf: Hydraulics diagram
NOTE:
Refers to the numbering on the hydraulics diagram

5.2 Hydraulic Drawing

5.3 Hydraulic Pump
(Please see hydraulics diagram in section 4.1)
An electric motor (24 VDC) [no. 7] drives the pump [no. 6] of the hydraulic system.
The pump is directly connected to the rotating shaft of the electric motor [no. 7].
The pump is only running when some of the hydraulic valves (MV 1.1, MV 2.1, MV
2.2, MV 3.1) are on. When the MV 1.2 (foot down) is on, the system does not need
the hydraulic pressure as the foot applies gravity to be lowered.
Pressure Adjustments:
On the side of the hydraulic pump under the red cover there is an Allen key to adjust
the oil pressure. The pressure should normally be adjusted to max. 100 bar on the
manometer [no. 2]. The pressure is raised clockwise. The pressure is lowered
anticlockwise.
NOTE:
If the pressure exceeds 120 bar, the hydraulic system may be severely damaged.
Screw to adjustment of oil pressure

5.3.1 Hand Pump and Emergency Operation
The manually operated hydraulic pump

[no.13] can be used if the hydraulic system or
the electronics fails.
When raising the foot, the foot should be

raised until a loud and clear mechanical click
is heard. This indicates that transport locks 1
and 2 are in the correct position.
5.4 Oil filter
The hydraulic system has 1 oil filter, the filter

is placed on the hydraulic side.
When replacing the oil filter, also change the

hydraulic oil.
5.5 Hydraulic Cylinder
(See hydraulic diagram in 4.1)

Four hydraulic cylinders operate the foot, the
weight assembly and the transport lock.
Two cylinders operate the foot assembly [no. 27

and 27a]. Both cylinders are so-called one-way
cylinders, which are connected in parallel. When
the foot is lowered, they work by means of
gravity. The valve MV 1.2 is then opened for
release to the tank and the foot will be lowered
without using hydraulic pressure. When the foot
is to be raised again, hydraulic pressure is put
on MV 1.1.

The weight cylinder [no. 26] are a so-

called two-way cylinder controlling a
magnet, which is activated to raise
the falling weight while testing.
When the weight cylinder are to raise

the magnet (falling weight), valve MV
2.1 should be used. When the weight
cylinder are to lower, the magnet
(falling weight), valve MV 2.2, should
be used.
The transport lock cylinder [no. 41]

are mounted under the base plate for
the buffers. To get to the transport
lock cylinder, the foot, load cell
assembly and bottom plate must be
dismounted.
The picture is taken from underneath
and after dismounting of foot, load cell
and bottom plate.
When the transport lock cylinders are

to work freely, valve MV 3.1 should be
used. When the transport lock
cylinders are to be locked again,
valve MV 3.1 should be released. In
this way, the cylinder is depressurized
and as the cylinders are influenced by
the spring all the time, the transport
lock automatically locks as soon as it
reaches the point where the two lock
catches can be locked and thereby
put the FWD in the transport lock
position. The picture is taken before
the hydraulic cylinder for foot
up/down, and sensor for locks are
mounted.

5.6 Hydraulic Valve
The hydraulic valves are mounted on the

same unit as the hydraulic pump and tank.
The valve block consists of a 4-way

directional control valve [no. 15] for the foot
cylinders.
A control valve [no. 17] adjusts the speed

when raising and lowering the foot cylinder.
A 4-way directional control valve is used for
the weight cylinder and a 2-way directional
control valve [no. 47] for the transport lock
cylinder.
All three valves can be operated manually by

pushing the button at the end of the valve.
CAUTION:
Do not push the valves with a sharp tool – this would damage the valves

5.7 Hydraulic Pressure Switch
The hydraulic pressure switch [no. 53]

PSI senses when the foot is lowered.
The PSI is depressurized, when the
foot is being lowered onto the
pavement surface and the FWD can
start the test sequence. This pressure
switch has been adjusted at the
factory. If the sensor needs to be
adjusted, the place the foot on
pavement surface and adjust the
sensor by means of the red screw so
that terminal no 4 (red led) in main
box A is signalling.
5.8 Cable for Beam
The cable lowers and raises the

geophone beam simultaneously with
the foot. When the FWD trailer is
connected to a towing vehicle and the
foot is lowered, be aware that the
geophone beam wire is free of the
geophone beam at the front end. If this
is not the case, adjustments can be
made by moving the geophone beam
lock fitting up and down.

Part 6: Electrical system

6.1 Electrical System
The 24 VDC electric systems consist mainly of the following:
• Power supply
• Power battery
• Digital input (misc. non-contact switches)
• Digital output (misc. relays)
• Analog input (misc. transducers)
All these signals I/O are connected in various junction boxes and all ends in box A
All digital I/O in box A

All analog input in the RIO/CPU inside box A
All digital I/O signals are transmitted from and to box A.
A B
(A) In box A, terminals 1-14 show the FWD digital input status from all non-contact switches
by means of a red light diode on the terminal block.
(B) The FWD digital output status can be read on relays K1-K10 by means of a green light
diode in the relay.

The key switch on/off cuts off the main relay S1 and all power
supply to the electric system.
The manual control box can be dismounted by means of a

Burndy plug on box A.
Emergency switches S1 and S2 cut off all digital outlets by

cutting off the power supply to all outlet relays K1–K10.
Part 7: Non-contact Switch

All movement sensors are non-contact proximity switches (PNP type). The switch is normally
open, which means that the switch gives a 24 VDC signal when activated. Minimum sensing
distance is 3 mm. However, Sweco Pavement Consultants recommends adjustment to
approx. 2 mm.
Non Contact Inductive Switch

ca. 2 mm. (min. 3mm.)
+ 24Vdc Power supply (brown wire)

-24 Vdc power supply (blue wire)
Signal out +24Vdc (black wirw)
Lock from rear end
Red light diode on when signal is on.
Figure 21 Non contact switch
Below a description of each individual switch and its position follows:
F2: Magnet is down

This switch senses whether the magnet (falling weight cylinder) is in down position.
Magnet down and attached to weight.
The switch is located at the bottom of the falling weight cylinder.
CAUTION: The falling weight must be in safety position when changing or adjusting
this switch!

F3: Release lock (lower switch)

This switch senses, whether the foot is sufficiently
lowered so that the hydraulics can release the
transport locks. In this way it can be automatically
locked when the foot is raised. The switch is located
on the left side of the FWD on the FCU box.
F3 Release lock (lower switch)
F5: Lock 1 is on
This switch senses, whether the transport lock in the right side
of the FWD is locked. The switch is located in the right side of
the FWD at the hydraulic cylinder for the foot. This switch is
mounted on a special armature. When the switch needs to be
changed or adjusted, this armature must be dismounted in
order to get to the switch.
F6: Beam is up
The switch senses, whether the beam is up at the
front of the FWD. The switch is located at the front of
the FWD at the beam lock. When adjusted, it should
give a signal when the beam is up and in lock
position.

F7: Lock 2 is on
This switch senses, whether the transport lock in the left side of the
FWD is locked. The switch is located in the left side of the FWD at the
hydraulic cylinder for the foot. This switch is mounted on a special
fitting. When the switch needs to be changed or adjusted, this fitting
must be dismounted to get to the switch.
F8: Foot is up (upper switch)

This switch senses, whether the foot is in top
position so that the transport locks can be locked.
The switch is located in the left side of the FWD at
the FCU box. When changed or adjusted, the switch
must be placed in a position that allows the transport
locks to be locked and move freely. When lowering
the foot, this means that the foot has to be raised
approx. 5-6 mm before lowering in order to allow the
transport locks to be released without the foot
resting on them.
The switch should switch ON/OFF approximately

midway through the free foot movement when the
transport locks are activated.
F8 Foot is up (upper switch)
F9: Weight is down

This switch senses, whether the weight is down
(when the magnet has dropped the weight). At the
same time, this switch triggers the data collection
electronics for geophones 1-18, load cell and
temperature. The switch is located at the base plate
for the foot assembly. When adjusted, it should be
placed approx. 5 cm above the buffer height.

F10: Manual temperature in holder

This switch senses, whether the manual
temperature probe is placed properly in its holder.
If the manual temperature probe is not
placed in the holder and F10 does not give a
signal, the foot cannot be raised after end
of sequence. The switch is located
in front of the filter in the right side of the FWD.
F10 Manual temperature sensor in holder
F11 (F25) and F12

Trigger from chainage counters A and B.
The two inductive switches, which are alternated by
steel plates mounted on the rim. The sensors are
mounted behind the left front wheel. By using two
transducers the direction of movement can be found.
The distance is measured by counting the
revolutions of the trailer wheel.
F13 and F14

Cover plates on
Both switches are activated by the cover plates. If
the plates are not mounted, it is not possible
to use the FWD. This is a safety precaution
and in accordance with an EU directive
on machine safety.

Part 8: Height Transducers

The height transducer is an ultrasound
sensor, placed at the bottom of the foot unit.
The signal from the ultrasound sensor is

transferred into an electronic analog card 1
(box A)
Part 9: Pressure Switch

The pressure switch is located to the left of
the hydraulic tank.
This switch gives a signal when the foot is

down. When the hydraulic system for the foot
cylinder is depressurized, the pressure switch
gives an on-signal.
At the top of the switch is a small metering

screw. The switch should give a signal when
the foot is on the pavement and all the
hydraulic pressure is released from the foot
cylinder.
Part 10: Relay

The electric control includes a number of relays, which are mainly controlled by the CPU-
card via the I/O-card.
10.1 Relays K1-K10
Relays K1 to K10 have

integrated light diodes
signalling when the relays
are activated.
Relays K1-K10 are located
on the left side of box A.
10.2 Relay K21 for hydraulic motor
The relay for the hydraulic motor MG2 is located on the right
side of the FWD.
10.3 Main relay

Main relay RL0 is located at the bottom of box A

Part 11: Fuses

11.1 Main fuse
In the electric system fuses are located as follows:

Main fuse box is located behind the hydraulic pump.
Fuse no. F1: Main fuses to the entire FWD (100 A)

11.2 Fuses Box A
Fuse no. F2:

This fuse powers the following:
Size 2 A
CPU/RIO
All non-contact switches
Height transducer
Main control box all inputs
Relays K1 to K10 and K 20
Load cell
Fuse no. F3:

Size 13 A
All hydraulic valves (MV1.1 /MV1.2/MV 2.1/MV2.2/MV3.0)
Magnet lock for beam M6
Fuse no. F4:

Size 13 A
Hydraulic pump K21
Warning light P3&P4
Magnet for weight M9
Spray mark M 10 (option)

Part 12: Load Cell and Geophones
12.1 Load Cell
The load cell is located right above the foot of the FWD with
a high-quality Lemo plug for quick (dis)mounting.
Load cell
Follow below procedure when dismounting the load cell, e.g. in connection with dismounting
of geophone no. 1:
1. Make sure that the foot is up and locked in transport position.
2. Loosen the two screws holding the foot.
3. Lower the foot until it touches the ground.
4. Now the foot can be turned clock-wise by means of the two handles on the foot and the
foot can be dismounted from the FWD.
5. Hoist the foot into transport position. NOTE: The foot is heavy. (About 15 kg)
6. The load cell with the geophone peak for geophone no. 1 in the middle is now visible.
The load cell is mounted with three 8 mm Allen screws.
7. Dismount the Lemo connector at the load cell and the three Allen screws. Now the load
cell is loose and dismountable. If it is stuck, a moderate hit with a rubber hammer may
loosen it.
Geophone no. 1 can now be dismounted after the

connector for geophone no. 1 has been taken off box F.
Follow the above procedure (1-7) backwards when mounting the load cell that is 7-1. It
should, however, be noticed that when the load cell is fastened with the 3 Allen screws (step
7), this should be done transversely and it must be fastened with a moment torque spanner.

12.2 Seismic Geophone
The FWD can be mounted with 1-18 geophones. Normally, the FWD has 9 geophones. The
geophones are located in the centre of the foot arrangement and on the geophone beam
respectively. Geophone no. 1 is always located in the centre of the foot.
Geophones 2-9 (18) are located on the geophone beam. The 17 geophones on the beam
can be adjusted from 19-250 cm, measured from the centre of the foot.
The physical location of the beam must be in accordance with the geophone setup in the
data collection program (system configuration).
Dismounting of Geophones:
For instance, calibration and checks require dismounting of the geophones from the metal
housing and foot.
Geophones 2-9 (18):
Geophones 2-9 (18) are mounted in metal housings, which are mounted on the geophone
beam. When dismounting geophones from these, the following should be done:
1. Dismount the geophone housings from the beam and their connectors in box F.
2. Separate metal housing and geophone from each other by dismounting the nut at the
top of the metal house.
3. The geophone can now be separated from the metal house.
Now the geophone is ready for e. g. calibration.
Geophone Centre geophone
Part 13: Temperature Sensor

The FWD is mounted with 3 temperature sensors as standard:

Air temperature
Surface temperature (optimum IR)
Manual temperature
The three temperature sensors are of a high accuracy DT100 type and capable of measuring
from 0-100C.
13.1 Air temperature:
The air temperature sensor is located on the car in such

a way that it avoids direct sun and so that air can pass
by it.
13.2 Surface temperature:
The surface temperature sensor is placed on the

geophone beam. In this way the surface temperature
sensor gets in direct, physical contact with the road and
measures the surface temperature when the
geophones are lowered and placed on the road.
Option:
An IR sensor can be mounted under need the vehicle.
This IR sensor can measure the surface temperature,
without touching the surface.
13.3 Manual temperature sensor:
The manual temperature sensor is placed in a

holder next to the hydraulic pump.

When a measuring sequence has been carried out in the data collection
program, the road temperature can be measured by means of the manual
temperature sensor.
1. Drill a 5 mm hole in the road and pour a mixture of water and glucose into
it.
2. Plug the manual temperature probe into the hole.
3. Wait until the temperature has become stable.
4. Place the temperature probe in its holder again.
NOTE:
If the temperature probe is not placed correctly in its holder, the foot cannot be raised
into its transport mode position. This precaution protects the probe against damage if
you try to leave the measuring spot while the probe is still in the road.
Part 14: SBC SYSTEM

14.1 SBC System (Single Board
Computer) Software
The system is constructed

around a CPU-unit. The CPU-
unit is located in box A.

RIO/FCU unit
The CPU-card provides the following:
A) Communication to PC note book computer

B) Communication to A/D-card and I/O-card
C) Control of all mechanical functions
The communication cable is a standard Ethernet RS 45 communication cable.
The FWD has two machine modes or “working modes”:
• Auto mode
• Manual mode
In auto mode, some of the keyboard functions (manual keyboard) are locked.
In manual mode, some of the PC commands are locked. Auto mode is used
when driving and measuring. Manual mode is mainly used in case of
workshop servicing of the FWD.

14.2 A/D-card
The analog-/digital card receives all analog signals:
Geophones 1-18
Load cell
Air temperature
Surface temperature
Manual temperature
Weight height transducer
14.3 Digital I/O card
The I/O card controls the entire digital input signal and digital output signal
from/to the CPU card.
magnet Relase Foot is Lock 1 Beam Lock 2 Foot is Weight Man.temp Trig from Trig from Covering Covering From
is lock down is on is up is on up is in holder dis. dis. countt is ON is ON man. box
countt
Control signal
in to I/O card
I/O CPU
Card Card
Control signal
out from I/O card
RL 1 RL 2 RL 3 RL 4 RL 5 RL 6 RL 7 RL 8 RL 9 RL 10 Man.box
Magnet up Magnet Foot up Foot down Lock 1+2 Lock beam Hy-pump on Warninglight Magnet on Spraymark ligh
down off on Aut/man.t
Digital I/O Chart

Part 15: Preparing/Checking the FWD before

Measurements
It is important that a thorough check/preparation of the FWD is carried out well in advance of
the measurement of a road section. If this is not done, there is a risk that a whole day’s
work/measurements are useless or lost.
Preparing/checking can be divided into the following areas:
• Vehicle
• Generator/battery
• FWD mechanics/hydraulics
• Setup for weight/buffer
• Setup for geophones
• Software setup
• Practical test on test site
• DMI
15.1 Vehicle
Check the vehicle in accordance with the original vehicle manual (lights, brakes, engine,
tyres, etc.).
Top up the vehicle with petrol/diesel.
Check power inverter (220 V/110 V). (If mounted permanently on the vehicle).
Check warning lights (if any).
Check DMI (if any). We recommend using the same road section each time for this purpose,
for instance 1,000 m (accuracy 0.001%).
Check the 24V power supply from the 24V FWD alternator.
(Control lamp should not light when the car engine is running)
If the car/FWD is equipped with two 12/24 inverters, then make sure that the inverter
indication for power IN 12V and for power OUT 24V is turned on while the car engine is
running.
Both inverters have “overload” lamps. These will light up when the batteries are defect, in
case of low power, no connection, or if the inverter is defective.

15.2 FWD Mechanics/Hydraulics
Check oil level of the hydraulic tank. Top up if

necessary.
Before checking the hydraulic oil level, the
FWD foot must be in lower position. When
the foot is down the indicator glass shall be
full of oil as shown on the picture.
Remove the lid

The type of hydraulic oil is Castrol Hyspin- and top up with
AWH32 or similar hydraulic oil from other hydraulic oil
brands standard hydraulic oil.
Max oil level

15.3 Check the FWD in manual mode
Switch on the FWD by turning the main key “ON”
Operate the FWD in manual mode by following the steps

below:
1. Press the Auto/ Man mode button and Keep it activated
during the next steps.
2. Press the button LOCK.
3. Turn the button left FOOT DOWN
4. Turn the button right MAGNET UP
5. Turn the button left MAGNET DOWN
6. Turn the button right FOOT UP
7. Release the Auto/ Man mode button
8. You should be able to hear lock 1 and lock 2 clicking when
the foot is in top position
The manual box is placed on top on the electronic box
Stand clear of all moving parts and do not allow observers to stand close to
the FWD while operating.

Part 16: Setup for Weight/Buffer

As to the FWD the below physical, basic rule applies:
There are 4 things which has an influence on the pulse time of the load signal.
• Layers of weight
• Number of buffers
• Drop height
• Pavement
This means that if the pulse time is to be changed then the weight, the area of the spring
element (rubber buffers) or the drop height has to be changed. The more weight the longer
the pulse time. The larger the area of the spring element the shorter the pulse time. The
higher drop height the shorter pulse time.
By changing weight, number of buffers or drop height, it is possible to achieve the desired
peak load level and still maintain load pulse duration of 25-35 ms (we recommend to work
with a pulse time of 27-34 ms) and essentially half-sine load pulse shape.
Do not forget to check that the correct setup is used for the measuring assignment in
question.
16.1 Setup for Buffer
By changing the number of buffers, it is possible to achieve the desired peak load level
(10-150 kN FWD/ 10 - 250 kN HWD/ 10-350 kN SHWD) and still maintain a load pulse
duration of 25-35 ms (we recommend working with a pulse time of 27-34 ms).
The buffers are all the same hardness, shore 50-55.
When mounting or dismounting of buffers, always make sure to have the same configuration
on each buffer plate.
See table section 16.2 Setup for Weight concerning target Load and load pulse time

Buffer plates without any buffers Buffer plates with 11 buffers on each side
Buffer plates with 9 buffers on each side Buffer plates with 7 buffers on each side
Buffer plates with 5 buffers on each side Buffer plates with 3 buffers on each side
When changing the buffers, follow the below procedure:

• Switch on the FWD by turning the main key “ON” and switch the safety key to
position 1.
• Take safety cover of, front and rear.
Remove the manual weight locks, Fig.1, from the holder and screw magnet and
weight together, Fig. 2.
• Lower foot and raise magnet with weights into top position.
• Turn the two locking devices in against the weight, Fig.3.
Take the safety locking device in.
Fig. 1 Fig. 2
NOTE:
Do not work with the buffers

until the safety locking
devices are in place.
Fig. 3

• Now it is possible to get access to the

buffers
• The buffers can be mounted/dismounted

by turning the buffers.
• Now it is possible to change the buffers

to the desired setup.
16.2 Setup for Weight
By changing weight it is possible to achieve the desired peak load level

(10-150 kN FWD) (10-250 kN HWD) (10-350 kN Super HWD).
The weight can be changed with 40 kilo intervals from 108 kilos (base weight) to 628
kilos (HWD).508 kilos (FWD).
FWD 10-150 kN is delivered with 10 layers

HWD 10-250 kN is delivered with 13 layers
SHWD 10-350 kN is delivered with 16 layers
Weight units: Total weight:
0 108
1 148
2 188
3 228
4 268
5 308
6 348
7 388
8 428
9 468
10 508
11 548
12 588
13 628
14 668
15 708
16 748

To change the number of layers of weight, follow the steps below:
• Remove safety cover.
• Loosen weight locks with a 19mm key by turning clockwise.
• Now weight can be removed or added. All in

accordance with setup.
• Make sure that the weight unit is locked when

weight is added.
• To lock the weights again, turn anti-clockwise on

weight locks.
• Remount safety cover.
16.3 Target Load and load time:
NB
The below loads and load times are only guiding values as the values can change quite
considerably. This depends on the kind of material to be measured on (asphalt, concrete,
gravel, etc.). Our specifications for the puls time is to be between 25-35 ms, but we
recommend to work with a puls time from 27-34 ms
Within specification
Within recommendation
Outside specification
3 x buffers
Falling height
Weight
Layer 100 200 300 400 500 600
16 x x x x x x
15 x x x x x x
14 x x x x x x
12 x x x x x x
10 x x x x x x
8 x x x x x x
6 42/49 78/42 112/38 146/32 180/28 193/27
4 41/45 67/40 96/34 125/30 153/26 166/25
2 33/38 50/34 69/31 88/28 106/26 115/25
0 21/31 36/28 46/27 56/26 66/24 70/23
kN/ms

4 x buffers
Falling height
Weight Layer 100 200 300 400 500 600

16 x x x x x x
15 x x x x x x
14 x x x x x x
12 x x x x x x
10 x x x x x x
8 x x x x x x
6 50/44 78/40 111/35 142/32 170/29 184/28
4 44/40 70/36 97/32 125/28 152/26 165/25
2 36/33 54/31 72/29 89/27 106/25 115/24
0 28/26 39/26 49/24 59/23,5 69/23 73/22
kN/ms
5 x buffers
Falling height
Weight Layer 100 200 300 400 500 600

16 x x x x x x
15 x x x x x x
14 x x x x x x
12 x x x x x x
10 x x x x x x
8 60/44 95/40 134/36 173/32 211/28 227/27
6 52/40 81/37 110/34 139/31 167/28 182/27
4 48/36 73/33 99/30 126/27 151/25 164/24
2 39/31 57/29 73/28 89/27 105/25 113/24
0 31/24 43/23,5 53/23 62/22 71/22 75/21
kN/ms
6 x buffers
Falling height

Weight Layer 100 200 300 400 500 600

16 x x x x x x
15 x x x x x x
14 x x x x x x
12 x x x x x x
10 69/45 112/40 159/36 205/32 250/28 271/27
8 63/41 97/38 136/34 173/31 209/28 225/26
6 56/37 84/34 114/32 142/30 169/27 190/25
4 51/34 75/31 100/29 127/27 151/25 165/24
2 42/29 60/27 77/26 93/25 109/24 118/23
0 30/23 46/22 56,5/22 65/21 74/21 78/20
kN/ms
7 x buffers
Falling height
Weight Layer 100 200 300 400 500 600

16 x x x x x x
15 x x x x x x
14 x x x x x x
12 x x x x x x
10 74/42 114/38 161/34 203/31 244/28 282/26
8 64/39 99/36 136/33 173/30 209/27 224/26
6 59/35 86/33 115/31 143/29 171/27 188/25
4 53/32 77/30 103/28 126/26 160/25 164/23
2 56/27 64/26 80/25 93/24 108/23 117/22
0 35/21,5 48/21 59/21 68/21 77/20 81/19
kN/ms

8 x buffers
Falling height
Weight Layer 100 200 300 400 500 600

16 x x x x x x
15 x x x x x x
14 x x x x x x
12 86/42 140/37 201/33 259/29 312/26 339/25
10 80/39 124/36 173/32 220/29 263/27 287/25
8 68/37 100/34 137/32 173/29 208/27 223/26
6 62/33 89/31 118/30 146/28 174/26 192/25
4 57/30 81/28 103/27 127/26 148/24 162/23
2 48/26 67/25 83/24 97/23 110/23 120/22
0 x x x x x x
kN/ms
9 x buffers
Falling height
Weight Layer 100 200 300 400 500 600

16 105/44 176/39 251/35 320/30 383/26 393/25
15 100/43 165/38 238/34 304/30 366/26 382/25
14 98/42 162/38 229/33 293/29 350/26 373/25
12 89/40 143/36 203/32 260/28 310/26 340/25
10 81/38 126/35 177/31 224/28 262/26 295/25
8 72/35 104/33 141/31 174/29 210/26 226/25
6 66/32 93/30 121/29 148/27 176/25 193/24
4 60/28 85/27 107/26 130/25 152/24 163/23
2 51/25 70/24 86/23 100/22 115/22 120/21
0 x x x x x x
kN/ms

10 x buffers
Falling height
Weight Layer 100 200 300 400 500 600

16 107/42 177/38 256/33 327/29 384/26 394/25
15 103/41 170/37 242/33 308/29 370/26 384/25
14 97/41 161/37 230/33 293/29 347/26 373/25
12 93/38 147/35 202/32 259/28 307/26 341/25
10 87/35 130/33 177/30 223/28 264/25 292/25
8 75/33 108/32 144/30 178/28 213/26 230/25
6 68/30 96/29 123/28 150/26 176/25 195/24
4 62/27 89/26 110/25 131/24 150/23 165/23
2 53/24 72/23 89/22 103/22 117/21 123/21
0 x x x x x x
kN/ms
11 x buffers
Falling height
Weight Layer 100 200 300 400 500 600

16 106/41 179/37 258/32 329/29 384/26 394/24
15 106/39 171/36 244/32 313/28 371/25 384/24
14 101/39 162/36 231/32 295/28 355/25 373/24
12 95/37 147/34 206/31 260/28 307/25 344/24
10 88/35 130/33 178/30 226/27 267/25 298/24
8 79/32 111/31 146/29 181/27 215/25 231/24
6 70/29 99/28 125/27 151/26 177/24 197/24
4 65/26 92/25 113/25 134/24 155/23 165/22
2 60/23 75/22 92/22 106/21 118/21 125/20
0 x x x x x x
kN/ms

16.4 Setup of geophones
Check whether geophones 1-18 are connected to the

right plugs. See the figure on the black box mounted on
the geophone beam.
Check that geophones are placed in the right order

2-18 (1 in centre of load plate) and in the right
distance 0-250 cm in accordance with the setup in
the software.
Check that all springs on geophone housings are

mounted correctly and work freely and that geophone
spikes are mounted correctly and are not worn.

Part 17: Trouble shooting
17.1 CONTENTS
• Troubleshooting:
o Car
o Foot arrangement
o Weight arrangement
o Control box
o Power supply unit
o Computer equipment inclusive of printer, etc.
o Temperature sensors
o Chainage counter
o Data reading
o Spray marking equipment

NB!
If an error occurs during start up or when operating with the PRIMAX, an error message will
normally pop up on the computer screen.
In cases where this error message is not enough to find an error, the below trouble shooting
procedure should be used:
1. Check battery (Voltage and water level)
2. Check all cable connections and try to connect the Ethernet cable directly to the RIO,
instead at the front end of the trailer.
3. Check all fuses (Part 11)
4. Check hydraulic liquid level (Section 15.2)
5. Turn off FWD and computer
6. Turn on FWD and computer
7. Check that it is possible to operate FWD in MANUAL mode
8. Check all non-contract switches (Part 7)
9. Check all relays (Part 10)
10. Check pressure switch (Part 9)
11. Check hydraulic valves (Part 15 Section 15.2)

17.2 Car - troubleshooting
Problem: Solution:
In case of any problems We recommend contacting the local car dealer in order to solve the
with the car. problem.

17.3 Foot arrangement - troubleshooting
Problem: Solution:
Foot cylinder not stopping in 1. Limit switch for foot up position is out of adjustment or defect.
upward direction travelling Adjust or replace sensor F8 (see Part7).
from initial position and
hydraulic pump keeps
pumping until "time out" signal
is displayed on computer
screen.
Foot cylinder stops in The hydraulic pressure switch is not working. Replace or adjust
downward position and (see Part 9).
sequence is interrupted
Foot cylinder stopping in

upward or downward direction Use the manually operated hydraulic pump to hoist the foot
and it is not possible to move arrangement into transport position (see Part 5 section 5.3.1)
foot in any direction.

17.4 Foot arrangement - troubleshooting
Problem: Solution:
Foot cylinder not running. 1. Check whether pump motor is running. If not, then
check motor fuse and motor relay in box A and main
fuse.
2. Check motor main relay (located to the left in front of

the hydraulic motor)
3. Check output status on relays K7, K5, K3, K4
4. Check whether red LED on valve connector foot down

is on.
Electro-magnet does not take Adjust switch (F2 magnet is down)

up weight
Check battery power level.
Weight cylinder does not stop Check if the ultra sound (height sensor) is working, try to
when reaching the set falling recalibrate the ultra sound sensor.
height

17.5 Weight arrangement - troubleshooting
Problem Solution
Weight Cylinder not able to run 1. Check whether hydraulic pump is running. If not, then
check fuse and relay in box A and main fuse.
2. Check output status on relay K7, K1, K2
3. Check whether the red LED on valve connector
Weight UP or DOWN is on.
“POWER ON” not lit, when key 1. Check main fuses and fuses in box A
is turned on 2. Check power relay K20 in box A.

17.6 Power supply unit - troubleshooting
Problem Solution
“FWD MANUAL PANEL” is not
working. Check all electric cards (plug/unplug the cards)
Accumulators not charging. 1. Check that voltage on generator is at approx. 27V when
the car engine is running
2. Check cable connection from generator to batteries and

repair if necessary.

17.7 Power supply unit – troubleshooting
Problem Solution
Accumulators not charging. Bad connection between snap terminal and accumulators.
Clean with steel brush and, if required, with boiling water.
Check charge of accumulators with acid test. If necessary,

recharge accumulators with external charger (24VDC) and
repeat acid test. If accumulators are defect, replace them.
OBS. Always replace both, if necessary, and always re-

charge both accumulators in 24VDC mode.
Generator running, and Accumulators are defect. Check by acid test and replace.
voltages is in order, but
accumulators not charging (see Connectors in bad shape.
photo in part 4.2)
If an error cannot be found/repaired, contact dealer or
Sweco Pavement Consultants directly.

17.8 Computer equipment – troubleshooting (including printer, etc.)
Problem: Solution:
No connection to FWD 1. Check that FWD equipment is switched on
equipment (error during send)
2. Is cable between computer and FWD equipment fitted
correctly?
3. Check whether all indicator lamps on power stabilisers

are on.

17.9 Data reading – troubleshooting - Temperature sensor
Problem: Solution:
Temperature reading 0 1. There is a short circuit in wiring from control box to
temperature sensors or in connector on geophone beam.
Repair or replace.
2. Plug for temperature sensor on control box is full of

water, which is causing a short circuit. Repair.
3. Temperature sensors are defect. Replace and send to

your dealer or direct to Sweco Pavement Consultants for
repair.
Temperature not reading 1. There is moisture in plug connection for temperature

correct value sensor on control box or in connector on geophone
beam. Repair.
2. Temperature sensors are out of calibration. Send to your

dealer or direct to Sweco Pavement Consultants for
calibration.

17.10 Chainage counter - troubleshooting
Problem: Solution:
Chainage counter not counting Check both wheel sensors - are LED lamps lit when metal is
up or not counting down held in front of them and then if both LEDs are not lit when
there is no metal (target). Replace if faulty. (See Part 7
section F11 and F12)

17.11 Data reading - troubleshooting
Problem: Solution:
No load readings
1. Check load cell cable. Repair if damaged.
2. Check whether weight trigger F2 next to weight is

active. (LED on when metal is held in front of it). (See
Part 7 section F2)
No reading on one or more 1. Check connectors from geophone to geophone card
geophones inside FCU box.
2. Interchange connector of faulty geophone with a

connector of one of the working geophones and check
whether the error moves with the geophones or stays
on the same channel.
a. If the error moves along with the change then the

geophone or wire is defect.
b. If the error is not moving, but stays on the same
channel, then the error is in the geophone card or
in the connection from box F for geophones to box
A.
Problem: Solution:
Drop is made but no readings Check, whether weight triggers F9 functions. Replace, if
are received. defect. (Part 7 Section F9)
Check status under License in bottom right corner of the
software. It shall be the name of the FWD, if it is DEMO the
connection between FWD and laptop is not working.

17.12 Marking equipment – troubleshooting
Problem: Solution:
Equipment not marking 1. Check that equipment is connected correctly
2. Spray has not been sufficiently shaken. Shake for at least 2

minutes 4 times a day during constant use and otherwise
before starting up equipment each time.
3. Spray can's nozzle is blocked. Clean or replace.
4. Electromagnet for marking equipment is not working

satisfactorily. Repair or replace.
Electromagnet cannot be 1. Fuse on side of box A has blown.
activated Investigate reason for this and replace with equipment fuse
2. Relay in control box is defect. Replace.
3. Electromagnet is faulty. Check by measuring to see if there is

24 VDC at coil, if it is defect, replace.
Marking equipment is Marking equipment is not adjusted correctly. Adjust by undoing
spraying a very large, unclear adjusting screw and move marking equipment up to obtain a
mark, or a small, "fat" mark. larger mark or down to obtain a smaller mark.

Part 18: Service and maintenance
18.1 Car
Service Daily Weekly Monthly Every 6 Annually As Remarks

months Required
Checking of lights x
and reflectors
Replacement of x
bulbs and reflectors
Checking of tyre
pressure (also x
spare wheel)
Follow the X X X X X x
maintenance plan
from the car
producer

18.2 Load Plate Arrangement

months required
Lubrication of load plate x x Grease

ball joint
Cleaning of load plate ball x

joint x Petrol
Cleaning and lubrication

of central post x With Teflon oil
x
Lubrication of transport x
safety lock of geophone x With Teflon oil
beam
General cleaning Water, soap

x x alcohol

18.3 Falling Weight Arrangement

months required
Cleaning of lifting x Dry cloth

magnet
Cleaning and lubrication

of FWD guide bar With Teflon oil
x
Replacement of weights x
Checking of rubber See spare

buffers (replace, if x x parts list
required)
Checking and lubrication

of With Teflon oil
transport safety lock x
Water/soap/alcohol
General cleaning x x

18.4 Control Unit

months required
Cleaning of operating
panel and x x Alcohol
bushes
Replacement of main fuses See spare

and motor relays x parts list
Replacement of fuses See spare

x parts list
Replacement of motor See spare

relays x parts list
Replacement of other See spare

relays x parts list
Replacement of other See spare

electric components x parts list
Cleaning of inner side of Vaccuum clea-

operating panel x ner

18.5 Power Supply Unit

months required
Checking of generator x
performance (lamp)
Batteries: Checking of
liquid level x
Batteries: Refill - liquid x Distilled

water
Batteries: Acid testing x x Battery tester
General cleaning Water/soap/

x alcohol
Check the power converter x

(12/24V)

18.6 Recording Equipment and calibration intervals
Service Daily Weekly Monthl Every 6 Every 2 As required Remarks

y months years
Absolute and traceable x See sec. 12.2

Calibration of geophones
Verification of geophones See sec. 12.3.

According to CROW
(Stacking tower test) x protocol “A”
Absolute and traceable x See sec. 12.1

Calibration of Loadcell
Checking of load cell x See sec. 12.1
Repeatability test x According to CROW

protocol “ B2”
Verification on reference x Set up a local reference

test point point
x 2-4 mm from weight

Checking of trigger position

18.7 Computer Equipment

months required
Cleaning of computer x Dry soft cloth

cover
Monitor
Cleaning of monitor
cleaner
x
Cleaning of disk drive Local dealer
Keyboard
Cleaning of keyboard x
cleaner

APPENDIX 1 Mechanical drawings

1.1 Main cylinder and magnet

1.2 Foot system

1.3 Base weight

1.4 Lock System

1.5 Buffer system

1.6 Main unit

USER MANUAL PRIMAX FWD/HWD – trailer-mounted
1.7 Main unit - detail
Sweco Danmark Pavement Consultants Page 93

1.8 Main unit - detail

1.9 Foot system

1.10 Base weight

1.11 Lock system

1.12 Guidance Bars

1.13 Magnet and main cylinder

1.14 Main magnet

Sweco Primax Trailer Manual 18-04

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PRIMAX Falling Weight Deflectometer

PRIMAX trailer version

Instructions for PRIMAX 7-150 kN, 7-250 kN, 7-350 kN

I. Condition of use ............................................................................................................................................ 8

Part 0: Safety ........................................................................................................................................................ 9

Part 1: Introduction ......................................................................................................................................... 14

Part 2: Technical Specifications ................................................................................................................... 17

Part 3: Hardware manual .............................................................................................................................. 22

Part 4: System Powering ............................................................................................................................... 25

Part 5: Information on Hydraulic system ..................................................................................................... 30

Page 2 Sweco Danmark A/S, Pavement Consultants

Part 7: Non-contact Switch ........................................................................................................................... 38

Part 8: Height Transducers ........................................................................................................................... 43

Part 9: Pressure Switch ................................................................................................................................. 43

Part 10: Relay ................................................................................................................................................. 43

Part 11: Fuses ................................................................................................................................................. 45

Part 12: Load Cell and Geophones ............................................................................................................. 48

Part 13: Temperature Sensor ....................................................................................................................... 49

Part 14: SBC SYSTEM .................................................................................................................................. 51

Part 15: Preparing/Checking the FWD before Measurements ................................................................ 54

Part 16: Setup for Weight/Buffer .................................................................................................................. 57

Part 17: Trouble shooting .............................................................................................................................. 67

Sweco Danmark A/S, Pavement Consultants Page 3

Part 18: Service and maintenance ............................................................................................................... 80

APPENDIX 1 Mechanical drawings ............................................................................................................. 87

Page 4 Sweco Danmark A/S, Pavement Consultants

DOCUMENT CHANGE RECORD

Sweco Danmark A/S, Pavement Consultants Page 5

User manual: PRIMAX FWD 1.00

© Sweco Danmark A/S, Pavement Consultants, Kokbjerg 5, DK-6000 Kolding

This edition was first published in 2009

All rights reserved; no part of this publication may be

Printed in Denmark by Sweco Danmark A/S

Page 6 Sweco Danmark A/S, Pavement Consultants

Liabilities, which cannot be excluded, is reduced to the full extent lawful.

Sweco Danmark A/S, Pavement Consultants Page 7

Subject to the provisions in this section, Sweco warrants that:

No liability for consequential damages:

Page 8 Sweco Danmark A/S, Pavement Consultants

0.1 Safety Alert Symbols

Caution and warning: Sign on Generator, to be observed if a generator is mounted on

Sweco Danmark A/S, Pavement Consultants Page 9

0.2 Responsibilities of equipment owner

0.2.1 Safety information

Make safety information available to equipment users in accordance with governing

0.2.2 Instructions, requirements, and standards

Provide appropriate emergency and first aid equipment.

Conduct safety inspections to ensure required practices are being followed.

0.2.3 User qualifications

Owners of equipment are obliged to ensure that users:

Page 10 Sweco Danmark A/S, Pavement Consultants

0.3 Safety Practices

0.3.1 Intended use of equipment

• Do not modify the equipment

0.3.2 Instructions and safety messages

0.3.3 Installation practices

• Check Plate-low alarm connection

Sweco Danmark A/S, Pavement Consultants Page 11

• Place computer conveniently for operator

• Do not cover ventilation grids of computer

0.3.4 Operating Practices

0.3.5 Maintenance and repair practices

Page 12 Sweco Danmark A/S, Pavement Consultants