Fayat DYNAPAC F1000T T4f, Operation & Maintenance Manual

Page 1: ...F1000T T4f Edit 2 April 2016 4812243646 A4 4812247168 A5 OPERATION MAINTENANCE Paver Finisher EN Keep for later use in document compartment Valid for ...

Page 2: ...www G QDSDF com ...

Page 3: ...ect use and application A1 B Vehicle description B1 1 Application B1 2 Description of assemblies and functions B2 2 1 Vehicle B3 3 Danger zones B6 4 Technical data standard configuration B7 4 1 Diemensions B7 4 2 Allowed angle of rise and slope B8 4 3 Permissible approach angle B8 4 4 Weights F1000T B9 4 5 Performance data B9 4 6 Engine B10 4 7 Hydraulic system B10 4 8 Material compartment hopper ...

Page 4: ...gulation for transportation C1 2 Transportation on low bed trailers C3 2 1 Preparation C3 2 2 Driving onto the low bed trailer C6 2 3 Secure the paver on the low bed trailer C6 2 4 After transportation C7 3 Transportation C8 3 1 Preparations C8 3 2 Driving mode C11 4 Loading by crane C13 5 Towing C15 6 Safety parking the vehicle C16 D 1 0 Operation D1 1 Safety regulations D1 2 Controls D2 2 1 Oper...

Page 5: ... during paving D134 2 2 Malfunctions on the paver or screed D137 E Set up and modification E1 1 Special note on safety E1 2 Auger E2 2 1 Height adjustment E2 2 2 Auger crossbeam Hydraulic height adjustment E2 2 3 Auger extension E3 2 4 Mounting extension parts E4 2 5 Mounting support tube extensions E5 2 6 Installing tunnel plates E6 2 7 Installation additional braces E7 3 Screed E8 4 Electrical c...

Page 6: ...e intervals F13 1 2 Points of maintenance F14 F 5 0 Maintenance Engine F18 1 Maintenance Engine sub unit F18 1 1 Maintenance intervals F19 1 2 Points of maintenance F21 F 6 0 Maintenance Hydraulic system F31 1 Maintenance Hydraulic system F31 1 1 Maintenance intervals F32 1 2 Hydraulic system F33 1 3 Points of maintenance F34 F 7 0 Maintenance Track F42 1 Maintenance running gear F42 1 1 Maintenan...

Page 7: ...0 F 10 0 Maintenance Decommissioning F61 1 Test check up cleaning stopping F61 1 1 Maintenance intervals F62 2 General observation F63 3 Check performed by a specialist F63 4 Cleaning F64 5 Preservation for storage of paver F65 5 1 Downtime up to 6 months F65 5 2 Downtime between 6 months and 1 year F65 5 3 Re commissioning F65 F 11 0 Lubricants and Operating Substances F67 1 Lubricants and operat...

Page 8: ... user within the meaning of the present operating instructions is defined as any natural or legal person who either uses the paver himself or on whose behalf it is used In special cases i e leasing or renting the user is considered the person who in accordance with existing contractual agreements between the owner and the user of the paver is charged with the observation of the operating duties Th...

Page 9: ...iption 1 Application The Dynapac F1000T is a rubber track paver that is used for laying bituminous mixed material roll down or lean mixed concrete track laying ballast and unbound mineral aggregates for paving foundations ...

Page 10: ... 7 Standard Track drive wheel 8 Standard Leveling cylinder for paving thickness 9 Standard Leveling arm guide 10 Standard Guide roller Side arm tow point 11 Standard Idler 12 Standard Screed side arm 13 Standard Auger 14 Standard Screed 15 Standard Power pack enclosure 16 Standard Engine exhaust fume extraction 17 Standard Operator s platform 18 Standard Operator s panel 19 Standard Warning beacon...

Page 11: ... and spread it with augers to allow the screed to spread the materials evenly The adjustable hydrostatic drive system allows the speed of the paver to keep pace with other equipment in all work conditions The operation of the paver is largely facilitated by the easy to use operator controls The operator can control the functions of the paver from either the left control panel or the right control ...

Page 12: ...es allow the paver to be turned on the spot The electronic synchronization controlled from the operating panel ensures that the paver runs straight ahead The operating panels can be secured in variable positions on both left and right console panels by a locking mechanism Steering is accomplished merely by driving one track at a different speed than one other If turning left the track on the right...

Page 13: ...o easily adapt to the different paving widths Leveling slope control system The slope control system allows the paving thickness to be regulated at the regulated at the left hand or the right hand side with a defined difference to the opposite side To determine the actual value the two screed leveling arms are linked with a slope beam The slope control system always operates in conjunction with th...

Page 14: ... Danger zones In the working areas around the machine marked in red there may be a risk of drawing in or crushing during normal operation caused by rotating and conveying elements or by components in motion ...

Page 15: ...B 7 4 Technical data standard configuration 4 1 Dimensions For screed technical data refer to the screed operating instructions ...

Page 16: ...Before operating your machine in an inclined position gradient slope lateral inclination which is above the specified limit value please consult the customer service department for your machine 4 3 Permissible approach angle with truck hitch ...

Page 17: ...5 Performance data Screed used Basic width Minimum paving width Continuously hydraulically adjustable up to Maximum working widths with extension parts Carlson EZ IV 1019 10 3 05 10 3 05 19 5 79 25 7 62 ft m Carlson EZ III 10 10 3 05 10 3 05 17 5 18 24 7 3 ft m Carslon EZR 10 10 3 05 10 3 05 19 5 5 94 26 7 92 ft m Maximum transport speed travel 10 16 9 mph km hr Operating speed Paving 1800 rpm 0 1...

Page 18: ...tem conveyor hydraulic cylinders Generator system Vibration system Hydraulic oil tank capacity 50 Gal 189 lt Hydraulic oil filling volume 80 Gal 303 lt 4 8 Material compartment hopper Volume approx 235ft3 6 65m3 Dumping height center outside 16 in 406mm 27 in 686m3 4 9 Electrical system On board voltage 24 VDC Batteries 2 x 12 V 32F 1050 RC 195 Alternator 24V 70A Generator 110 220 34kw 60Hz 4 10 O...

Page 19: ...ger control Dual independent proportional augers 4 13 Permissible temperature ranges Maximum Ambient Operating Temperature 120 F 48 9 C For the capacities for the various lubricants and operating substances see chapter F ...

Page 20: ...B 12 5 Location of instruction labels and identification plates ...

Page 21: ...ilure to follow the instructions or heed the warnings could result in injury or death Contact your Dynapac dealer for replacement of manuals Proper care is your personal responsibility 3 Warning Keep a safe distance from rotating fans Do not work around or on the fan when fan is in operation Rotating fan blades can cause severe injury or death 4 Filler neck for diesel fuel Located on both sides of...

Page 22: ...n cause burns or personal injury Do not come into contact with hot parts or components Wear protective clothing or protective equipment 10 Wear ear protection when using the machine Hearing damage could result from high noise level when ear protection is not used 12 Warning Do not drive the machine while standing Severe injury or death from an unseated position could occur Always use seat and seat...

Page 23: ...tion 14 Ultra low sulfur diesel only 15 Warning Crush area Keep a safe distance when machine is running or moving Do not work in this area when the machine turns or machine parts move Crushing can cause severe injury or death ...

Page 24: ...le identification number on the paver must match the product iden tification number B 16 Item Designation 1 Paver 2 Paver type 3 Mass of the base machine with all standard equipment kg 4 Paver rated power kW 5 Year of manufacturing 6 Product identification number PIN ...

Page 25: ...ding to the 2000 14 EC and ISO 3744 Sound pressure level at the operator s position at the height of the head LH Console RH Console LAF 83 9 dB A 83 dB A Sound capacity level LWA 102 dB A Sound pressure level at the machine Measuring point 2 4 6 8 10 12 Sound pressure level LAFeq dB A 66 7 69 68 9 68 6 68 7 68 9 6 2 Operating conditions during measurement The diesel engine was running at 2000 rpm ...

Page 26: ...ng surface with a radius of 52 5 ft 16 m The machine was at the center The measuring points had been assigned the following coordinates Measuring points 2 4 6 8 Measuring points 10 12 Co ordinates X Y Z X Y Z 0 7 0 7 1 5 0 27 0 27 0 65 0 65 11 36 11 36 B 18 ...

Page 27: ...B 19 ...

Page 28: ...Convert the protective roof if equipped and engage the latch Check that the clamping device for the auger crossbeam is fastened and that the telescopic tube cannot slide out see chapter E section 1 5 Pack all parts that are not permanently fixed to the paver and the screed into the appropriate boxes and into the hopper Close all coverings and check that they are securely seated When loading using ...

Page 29: ...o the side of the oncoming traffic and secured in this position The driving lights must be properly adjusted Only attachments and extension parts may be transported in the hopper no material If necessary the operator must be assisted by a second person when driving on public roads especially at road crossings and junctions ...

Page 30: ...n driving on an incline Attachment and loading equipment must meet the federal state and local safety regulations The weight of the paver must be taken into consideration when selecting the attachment and loading equipment 2 1 Preparations Prepare the paver for transportation see chapter D Remove all overlaying or loose parts from the paver and screed see also operating instructions for the screed...

Page 31: ...C 4 ...

Page 32: ...eed 5 Retract the screed to the basic width of the paver 6 Engage both screed transport safeguards 7 Lift the auger 8 Turn the ranage shift selector to zero 9 Turn the travel speed preselecting regulator to zero 10 Move the drive lever forward 11 Extend leveling cylinders completely 12 Set the drive lever to the center position ...

Page 33: ...oden blocks on the low bed trailer Turn the switch off Attach and secure the protective hood to protect the operating panel 2 3 Secure the paver to the low bed trailer Use only proper and permitted load fastening devices Use the four tie down points provided 1 2 These points have a tie down limit of 10 000 lbs 3545 9 kg each Wait until the exhaust extension pipe has cooled down then swing and secu...

Page 34: ...the exhaust extension pipe up and secure it Lift the screed to the transport position Start the engine and drive from the trailer at a low speed Park the paver in a secure spot lower the screed and switch the engine off Remove the key and cover the operating panel with protective hood then secure it ...

Page 35: ... basic widths also remove any attached side plates 3 1 Preparations Prepare the paver for transportation see chapter D Remove all overlaying or loose parts from the paver and screed see also Operating Instructions for the screed Store these parts in a safe place ...

Page 36: ...C 9 ...

Page 37: ...eed 5 Retract the screed to the basic width of the paver 6 Engage both screed transport safeguards 7 Lift the auger 8 Turn the ranage shift selector to zero 9 Turn the travel speed preselecting regulator to zero 10 Move the drive lever forward 11 Extend leveling cylinders completely 12 Set the drive lever to the center position ...

Page 38: ...C 11 3 2 Driving mode ...

Page 39: ... Operation 1 Turn the selector to position 3 2 Turn the pre selecting regulator to its maximum point 3 Use the drive lever to regulate the speed Press the emergency stop button when an emergency situation arises ...

Page 40: ...ter B for weights and dimensions Attachment and loading equipment must meet the conditions of the applicable accident prevention regulations The vehicle s center of gravity is dependent on the mounted screed Four lifting eyes 1 2 are provided for loading the vehicle with a crane ...

Page 41: ...arts from the paver and the screed until the basic width has been attained Remove all protruding or loose parts of screed and machine Attach lifting gear to the four attachment points 1 2 The max permissible attachment point load is Attachment point 1 20 000 lbs 9071 9 kg each for a total of 40 000 lbs 18144 kg Attachment point 2 20 000 lbs 9071 9 kg each for a total of 40 000 lbs 18144 kg Make su...

Page 42: ... be able to tow the machine Pressure for releasing the track drive system brakes is built up with the hand pump Do not release the track drive system brakes until the machine is sufficiently secured against accidental rolling or is already properly connected to the towing vehicle Pull the Handle A and turn the handle 90 and release Handle A to the DOWN position Pump the Handle B of the hand pump u...

Page 43: ... at a location accessible to the public it must be secured in such a way that unauthorized persons or playing children cannot damage the vehicle Remove the ignition key and main switch 1 and take it with you do not hide them somewhere on the machine Protect the operating panel with the dust cover and lock it Store parts and accessories in a safe place Do not turn the main switch off until 100 seco...

Page 44: ...s make sure during operation that no one is endangered by the machine Ensure that all protective covers and hoods are fitted and secured accordingly When damage is detected eliminate it immediately Operation must not be continued when the ma chine is defective Do not let any persons ride on the paver or the screed Remove obstacles from the road and the work area Always try to choose a driver posit...

Page 45: ...D 2 2 Controls 2 1 Operating panel Left Hand Operator s Panel Right Hand Operator s Panel ...

Page 46: ...drive units NOTE Use the turn signals when turning For precise adjustment see straight ahead travel trimming 2 Console lights Illuminates the instrument panels when the work lights are switched on 3 EIC Display for engine information diagnostic information and configuration Engine Information Center ...

Page 47: ...D 4 PANEL A 10 14 11 Left Hand Operator s Panel 12 13 15 14 11 Right Hand Operator s Panel 13 12 15 ...

Page 48: ...meter in the corresponding direction until the required steering angle is achieved Straight ahead travel trimming in speed level 3 Set the steering wheel to position 0 then adjust the potentiometer until the paver is traveling straight ahead NOTE Automatic straight ahead travel trimming takes place in preset speed levels 1 and 2 14 Truck hitch Opening and closing the truck hitch device at the fron...

Page 49: ...D 6 PANEL B Left Hand Operator s Panel Right Hand Operator s Panel ...

Page 50: ...set with the travel drive engine pre selector switch and with the travel drive pre selector The floating position function is only active when the drive lever is moved from its central position If the drive lever is moved to the central position the paver automatically switches to screed stop lock The auger conveyor clean mode only operates when the drive lever is in neutral position The auger con...

Page 51: ...D 8 PANEL B Left Hand Operator s Panel Right Hand Operator s Panel ...

Page 52: ...his function Toggle the switch down Manual regeneration ON Regeneration will be activated if the diesel particulate filter soot levels are high enough to allow regeneration The diesel particulate filter LED located on Panel E will be lit either static or blinking throughout the regeneration process Refer to Item 56 for more information regarding the LED function Close attention to the diesel parti...

Page 53: ...D 10 PANEL B Left Hand Operator s Panel Right Hand Operator s Panel ...

Page 54: ...trol see Operating instructions for screed 29 Selector switch left right operating panel 19 active panel LED 20 To select the primary activated operating panel Toggle switch function To avoid operator errors only one operating panel left or right can be activated at any one time Toggle the switch left Left operating panel active Toggle the switch right Right operating panel active 30 The active pa...

Page 55: ...D 12 PANEL C ...

Page 56: ... operator Conveyor OFF Toggle the switch back toward the operator Conveyor is at 100 feed capacity 42 Right conveyor OFF max output Overrides the conveyor function in automatic mode Toggle switch function Toggle the switch forward away from the operator Conveyor OFF Toggle the switch back toward the operator Conveyor is at 100 feed capacity 43 Left auger OFF max output Overrides the auger function...

Page 57: ...D 14 PANEL C 45 40 49 42 41 47 44 43 48 ...

Page 58: ...etween AUTOMATIC and MANUAL operating modes for the conveyor auger The left switch operates the left auger and conveyor while the right switch operates the right auger and conveyor Toggle switch function Toggle the switch forward away from the operator Operating mode AUTO LED ON The auger conveyor are switched on by moving the drive propel lever from the center position and are controlled by the r...

Page 59: ...D 16 PANEL C 45 40 49 42 41 47 44 43 48 ...

Page 60: ...forward away from the operator Raise auger Toggle the switch back forward the operator Lower auger Toggle both switches raise lower left right auger at the same time to keep the auger crossbeam level Do not raise or lower the auger until all equipment and persons are clear of the machine 49 Auger conveyor clean mode one fill Toggle between a slow cleaning mode and a fast fill speed for the auger a...

Page 61: ...D 18 PANEL D 53 52 54 51 55 50 53 52 51 50 ...

Page 62: ...Extend retract right screed extension Hydraulically retracts and extends the right extendable part of the screed Toggle switch function Toggle the switch left Retract screed extension Toggle the switch right Extend screed extension Do not extend or retract the screed until all equipment and persons are clear of the machine 52 Raise lower screed Hydraulically raises and lowers the screed Push butto...

Page 63: ...D 20 PANEL D 53 52 54 51 55 50 53 52 51 50 ...

Page 64: ...rator Lower the screed and switch to floating position During paving the screed must always be in its floating position This also applies to intermediate stops and truck changes As soon as the floating position function has been activated and the screed is lowered the screed lifting cylinder pressure is reduced The raise lower screed function can be carried out while the screed is switched to the ...

Page 65: ...D 22 PANEL D 53 52 54 51 55 50 53 52 51 50 ...

Page 66: ...to lower the screed Do not raise or lower the leveling cylinder until all equipment and persons are clear of the machine 55 Right leveling cylinder Manually extends and retracts the leveling cylinder when the vehicle is being operated without the automatic leveling system Toggle switch function Toggle the switch forward away from the screed Retract or raise the leveling cylinder to raise the scree...

Page 67: ...D 24 PANEL E 56 57 58 ...

Page 68: ...tremely hot process and could easily ignite combustible materials The diesel particulate filter may require servicing with prolonged use of the regeneration inhibit function If regeneration isn t completed and the filter continues to fill the LED will flash A manual regeneration should be started soon if the engine speed is not increased The regeneration inhibit switch should only be used if combu...

Page 69: ...D 26 PANEL E 56 57 58 ...

Page 70: ...y hot process Care should be taken to avoid contact with potentially hot surfaces 58 Regeneration inhibited Lit LED indicates that the regeneration system is inhibited by the activation of the regeneration inhibit switch Neither automatic nor manual regeneration can occur if this LED is lit Refer to Item 24 for more information on regeneration inhibit This function should only be enabled if a comb...

Page 71: ...D 28 PANEL E 56 57 58 ...

Page 72: ...ted for ISO 7000 registration To identify the container for diesel exhaust fluid NOTE The same symbol appears in the section Symbol Used on Containers or Fill Points To identify the display that provides information about the quantity of diesel exhaust fluid in the tank Engine emissions system failure or malfunction To indicate that the engine emissions system has failed or falls outside of specif...

Page 73: ...D 30 3 Auxiliary functions 60 61 62 63 ...

Page 74: ...he headlights ON only when the diesel engine is running 62 Release Agent fluid spray system ON OFF Activates the Release Agent fluid spraying system Toggle the switch up Turns on the sprayer Toggle the switch down Turns off the sprayer To prevent the battery from being drained switch the sprayer ON only when the diesel engine is running 63 Hazard warning flasher Push button to turn the Hazard Warn...

Page 75: ...e and various overall functions B RIGHT remote control Control certain functions on the right hand side of the vehicle and various overall functions C LEFT handset Removable handset for controlling certain functions on the left hand side of the vehicle D RIGHT handset Removable handset for controlling certain functions on the right hand side of the vehicle A C B D ...

Page 76: ...remote control The left remote controls the left auger and conveyor 70 71 72 74 76 78 80 82 84 86 88 90 91 92 93 94 70 71 73 75 77 79 81 83 85 87 89 90 91 92 93 95 The right remote controls the right auger and conveyor ...

Page 77: ...rial is sensed is 10 of its highest possible speed Knob function Turn the knob clockwise to raise the speed Turn the knob counter clockwise to lower the speed 74 Left conveyor pile height Manually adjusts the percentage of maximum speed in auto mode If 10 is selected then the maximum speed when no material is sensed is 10 of its highest possible speed Knob function Turn the knob clockwise to raise...

Page 78: ...5 The left remote controls the left auger and conveyor 70 71 72 74 76 78 80 82 84 86 88 90 91 92 93 94 70 71 73 75 77 79 81 83 85 87 89 90 91 92 93 95 The right remote controls the right auger and conveyor ...

Page 79: ...Auger 100 feed capacity 80 Left conveyor OFF max output Overrides the conveyor function in automatic mode Toggle switch function Toggle the switch forward away from operator Conveyor OFF Toggle the switch back toward the operator Conveyor 100 feed capacity 81 Right conveyor OFF max output Overrides the conveyor function in automatic mode Toggle switch function Toggle the switch forward away from o...

Page 80: ...7 The left remote controls the left auger and conveyor 70 71 72 74 76 78 80 82 84 86 88 90 91 92 93 94 70 71 73 75 77 79 81 83 85 87 89 90 91 92 93 95 The right remote controls the right auger and conveyor ...

Page 81: ...and per sons are clear of the machine 86 Left hydraulic tunnel extension retract option Controls the tunnel extension Toggle switch function Toggle the switch outward away from the screed Extends tunnel extension Toggle the switch inward toward the center of the screed Re tracts tunnel extension 87 Right hydraulic tunnel extension retract option Controls the tunnel extension Toggle switch function...

Page 82: ...9 The left remote controls the left auger and conveyor 70 71 72 74 76 78 80 82 84 86 88 90 91 92 93 94 70 71 73 75 77 79 81 83 85 87 89 90 91 92 93 95 The right remote controls the right auger and conveyor ...

Page 83: ...g the toggle switch ensure that equipment and per sons are clear of the machine 92 Raise lower extension scope Hydraulically raises and lowers the extension slope Toggle switch function Toggle the switch forward away from the operator Raise extension slope Toggle the switch back toward the operator Lower extension slope Before operating the toggle switch ensure that equipment and persons are clear...

Page 84: ...1 The left remote controls the left auger and conveyor 70 71 72 74 76 78 80 82 84 86 88 90 91 92 93 94 70 71 73 75 77 79 81 83 85 87 89 90 91 92 93 95 The right remote controls the right auger and conveyor ...

Page 85: ...Retract screed extension Before operating the toggle switch ensure that equipment and persons are clear of the machine 95 Extend retract right screed extension To hydraulically retract and extend the right extendable part of the screed Toggle switch function Toggle the switch left Retract screed extension Toggle the switch right Extend screed extension Before operating the toggle switch ensure tha...

Page 86: ...D 43 Left right handset 101 103 105 107 104 106 102 100 ...

Page 87: ...from the operator Raises the right screed side arm Toggle the switch back toward the operator Lowers the screed side arm Before operating the toggle switch ensure that equipment and per sons are clear of the machine 102 Left auger OFF max output Overrides the auger function in automatic mode Toggle switch function Toggle the switch right Auger OFF Toggle the switch left Auger 100 feed capacity 103...

Page 88: ...D 45 101 103 105 107 104 106 102 100 ...

Page 89: ...art of the screed Push button function Toggle switch left Retract screed Toggle switch right Extend screed Before operating the toggle switch ensure that equipment and per sons are clear of the machine 106 Handset connection cable Connects to the left remote control 107 Handset connection cable Connects to the left remote control ...

Page 90: ...e information diagnostic information and configuration 2 Soft keys Terminal is controlled by navigation through a set of four soft keys The keys are context dependent Soft key selection options are displayed above each key and are dependent on the current navigation location within the engine monitor software program 1 2 ...

Page 91: ... Main Menu screen 5 Exit back one screen Press to go back one screen 6 Select Press to make selection 7 Next Press to navigate to next digit or screen element As a general rule the far right soft key is the selector button and the far left soft key is the step back one screen key To engage full screen use the on screen selections are not displayed when not in use Press any soft key to display curr...

Page 92: ...nfo info fault log and J1939 lists Screen Setup PIN protected System Setup PIN protected Brightness Contrast Adjustment Adjust brightness and contrast levels by pressing the far left soft key This will display the brightness and contrast soft key bar Main Menu Start Menu The Main Menu screen is the starting point for configuring the termianl ...

Page 93: ...ate information Language Use Language to set the system language Units Use Units to set speed distance pressure volume temperature and fuel rates and economy settings Main Menu Basic Setup Use the Basic setup screen to set time language and display units for the terminal ...

Page 94: ...calendar style and time style Use up down select and next soft keys to navigate Main Menu Basic Setup Language Use Language screen to select program language Languages available English French German Italian Swedish and Spanish The default language setting is English ...

Page 95: ...ance km mi Pressure kPa bar lbs sq in Volume l gal imp gal Temperature C F Fuel Economy 1 100km mpg mpig Fuel Rate l h g h ig h Main Menu Basic Setup Units Use the up down select and next soft keys to define unit measurements ...

Page 96: ...D 53 Main Menu Diagnostics Use the Diagnostics screen to display current system in formation view and monitor fault logs and display all J1939 devices connected to the graphical terminal ...

Page 97: ...version current system version and node number Only information is displayed in the System Info window No changes can be made Main Menu Diagnostics Fault Log Fault information is saved and stored to the fault log Select either Active or Previous Faults to monitor fault activity Select specific faults to list more information ...

Page 98: ...ult Log Active and Previous Faults Selecting Active Faults in the Fault Menu will display all active faults on the CAN network Selecting Previous Faults in the Fault Menu will display all previously active faults on the CAN network ...

Page 99: ... and are no longer active will be shown in the current Active Faults log in italics Pop up fault alarms can be displayed by setting the Fault Pop Up to section of the System Main Menu Diagnostics Fault Pop Up Alarms When a fault is detected on the CAN network a flashing red warning alarm will be activated and a fault information pop up window will be displayed listing current fault information War...

Page 100: ...D 57 Main Menu Diagnostics Device List The Device list page will list all J1939 devices and addresses that are currently being monitored on the network ...

Page 101: ...isplay To select signals for display press the far right soft key Quick Data soft key Scroll through signal list using the up and down arrow soft keys and select de select signals for Quick View monitoring by pressing the far right check mark soft key Signals selected for display will show an asterisk to the left of the signal name ...

Page 102: ...D 59 Start Display Appears at system start Model Select Use the scroll buttons to select the appropriate paver model Once the check mark is on the correct model press OK ...

Page 103: ...n rpm with bar chart Diesel tank filling 3 in with bar chart Engine Coolant Temperature 4 in C Display 02 Display menu Hydraulic Oil Temperature 1 in C Engine Operation Hours 2 in hours Engine Coolant Level 3 in with bar chart Actual Engine Torque 4 in with bar chart ...

Page 104: ...nveyor POT 19 Right Conveyor POT 20 Left Auger POT 21 Right Auger POT Nr Source 10 Open circuit 11 Input at 0V 12 Short circuit 13 Input at 5V 20 Too low 21 Too high 30 No response 40 Invalid calibration 41 Invalid configuration Active Faults Display Appears when a fault occurs To see a list with active faults first use button 2 or 3 from the current screed and go to Active Fault Screen then press...

Page 105: ... driving Change console selector switch while machine in moving 7 Change active console when machine is stopped Change console selector switch while joystick is not in neutral 8 Change active console when joystick is in neutral Propel Selector in Position 4 Joystick is moved forward with no steering command for more than 5 seconds 9 Slope detection beyond the allowable limit 11 Beyond allowable sl...

Page 106: ...hort RH auger ultrasonic sensor open short Open 25 UltrasAugerRH_Open Short 24 UltrasAugerRH_Short LH conveyor potentiometer open short Open 27 Conv_PotLH_Open Short 26 Conv_PotLH_Short RH conveyor potentiometer open short Open 29 Conv_PotRH_Open Short 30 Conv_PotRH_Short LH auger potentiometer open short Open 31 AugerPotLH_Open Short 30 AugerPotLH_Short RH auger potentiometer open short Open 33 A...

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Page 148: ...viding the driver with a better view of the paving area in this position Release the platform lock 1 Swing the seat console to the desired position Engage the lock into one of the fixed positions 2 After locking the seat console check it to ensure it will not move into another position Dust cover The dust cover 3 can be stored on the bar 4 behind the seat ...

Page 149: ...eat is in the desired position release the lever and the seat will lock into place Seat back rest adjustment 2 The back rest can be adjusted to lean forward or lean back To adjust the back rest turn the knob on the lower front part of the seat Turn the knob clockwise to lean the back rest forward turn the knob counter clockwise to lean the back rest back Armrest positions 3 The armrest can be lowe...

Page 150: ...n fuse is located above the battery pack To switch the ignition off turn the key 1 to the left and pull it out Do not turn the main switch off until 100 seconds after the ignition has been turned off Lock the service doors covers To prevent the engine s electronic control module ECM from sustaining damage To avoid battery discharging To make it difficult for unauthorized persons to start and opera...

Page 151: ...t be pivoted upwards and the trans port safeguards for the hopper must be inserted Before parking or transporting the paver the hopper halves must be pivoted upwards and the trans port safeguards for the hopper must be inserted Without transport safeguards inserted the hopper halves will slowly open danger during transportation Mechanical screed transport safeguard to the left and the right beneat...

Page 152: ... Paving thickness indicator The Paving Thickness Indicator scales are located on the left and right sides of the vehicle The Paving Thickness Indicator 1 shows the setting on the Scale 2 In normal paving situations the same paving thickness should be set on both sides of the vehicle ...

Page 153: ...tor emulsion NOTE Check local regulations concerning use of cleaners and use of solvents Pull hose 1 out of the guide until there is an audible click The hose will lock in this position NOTE The hose will retract automatically into the guide by pulling out until it clicks again then it will reel in again On off switch 2 for the emulsion pump Press hand valve 3 to spray release to stop spraying The...

Page 154: ...witch hazard flasher 2 Activate switch 2 to switch on installed flasher Warning Beacon NOTE The function of the warning beacon must be checked daily before starting work Place the warning beacon onto the plug in contact and secure with a wing bolt 1 Slide the warning beacon with tube 2 to the desired height and secure with the both clamping screws 3 Turn the switch on to active the warning beacon ...

Page 155: ...sors control the material flow at the respective auger half The ultrasonic sensor is mounted to the side plate Loose clamping lever for adjustment and modify angle height of the sensor The cables must be connected to the remote control units located at the sides of the screed NOTE Adjust the limit sensor positions while the material is distributed Socket 24V Connect the working lights 24 V or othe...

Page 156: ...eavy extendable parts Diesel fuel Engine oil and hydraulic oil lubricants Separating agents emulsion and manual injector Shovel and broom Scraper shovel or scoop for cleaning the auger and the hopper intake area Necessary parts for extending the auger Necessary parts for extending the screed Percentage spirit level and leveling rail 4 yards 4 m long Leveling wire Protective clothing signal vest gl...

Page 157: ... Checklist for the machine operator Check How Emergency stop button Push in the button on the operating panel The diesel engine and all running drives must stop immediately on both remote control units Button must be pulled out to start machine again Steering The paver must follow every movement of the steering wheel Check straight running Horn Briefly press the horn button The horn must sound on ...

Page 158: ...side shields the side plates and the covers are securely seated Screed transport safeguard When the screed is lifted the operator must be able to engage both screed transport safeguards Hopper transport safeguard When the hopper is closed the operator must be able to engage both hopper transport safeguards Miscellaneous Check that the hoods and flaps are closed and secured Engine hood Lateral flap...

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Page 160: ...20 to the center position and the speed preselector 12 and the selector 21 for traction drive engine to minimum Insert the ignition key 10 in position 0 The lights should be switched off during starting to reduce the current drain on the battery Starting is not possible if the drive lever is not in the central position or if the emergency stop button 40 is depressed Turn the ignition key 10 into p...

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Page 162: ...ve lever 20 to the center position Set the speed preselector 12 and the selector 21 for traction drive engine to minimum Insert ignition switch 10 to position 0 to turn on the ignition Connect the power source with the appropriate cables Check for proper polarity Always connect the negative cable last and remove it first Turn the ignition key 10 completely to the right to start the engine Once the...

Page 163: ...D 120 ...

Page 164: ...ase the engine speed Set selector 21 for traction drive engine to position 2 Let the paver warm up for about 5 minutes if the engine is cold Read and follow Chapter D2 of this manual for possible warnings on the graphical terminal ...

Page 165: ...D 122 ...

Page 166: ...on drive engine to position 3 Set the preselector 12 for traction drive to approx 50 To start driving carefully tilt the drive lever 20 forward or backward according to the drive direction desired In case of an emergency press the emergency stop button 40 To stop the vehicle move the drive lever 20 into its center position Switching off and securing the paver Lower the screed using switch 52 Turn ...

Page 167: ...the screed plates 1 3 Preparation for paving Releasing agent Spray the parts coming into contact with asphalt hopper screed auger push roller with a separator emulsion Direction marks To ensure straight paving a direction mark must be present or established road edge chalk lines or similar Slide the operating panel to the desired side and secure it Pull the alignment indicator out of the bumper se...

Page 168: ...D 125 ...

Page 169: ...e to AUTO position Set the selector 21 for traction drive engine to position 1 and push the drive lever 20 forward away from operator The limit sensors for the conveyors and augers must switch off the function when the material has reached the height limit in the area beneath the auger crossbeam conveyor sensors or at the auger ends auger sensors Check that the material is being conveyed properly ...

Page 170: ...D 127 ...

Page 171: ...sition is activated now Observe the distribution of the material and adjust the limit sensors if necessary Set the compaction elements vibration and or tamper according to the required compaction ratio Let the paving supervisor check the layer thickness after 15 20 feet 5 6 meters and correct if necessary Carry out the check in the area of the drive chains or wheels as the screed tends to level an...

Page 172: ...he way Uniform material transport and distribution or supply to the screed may require corrections to settings of the material switches for conveyor and auger NOTE See the section D4 Malfunctions when paver functions fails Quality of the layer Mat thickness Slope Evenness in the driving direction and at right angles to it check with a level Surface structure texture behind the screed NOTE See sect...

Page 173: ...D 130 ...

Page 174: ...he center position Screed will be switched into STOP function automatically During extended interruptions i e lunch break Turn drive lever 20 to center position Move the preselector 12 and selector 21 to minimum position Screed will be switched into STOP function automatically Switch off conveyor auger 45 vibration 27 lights 25 and exhaust system 28 Switch ignition 10 off Switch screed heater syst...

Page 175: ...D 132 ...

Page 176: ...off Switch screed heater system off Remove the leveling units and stow them away in their boxes and close the boxes Remove all parts that extend beyond the paver width Secure them if the paver is to be transported over public roads on a low bed trailer 74 Do not turn the main switch off until 100 seconds after the ignition has been turned off The engine electronics require this length of time to b...

Page 177: ...much play in the mechanical screed link suspension paver speed is too high augers are overloaded changing material pressure against the screed Wavy surface long waves change in the material temperature segregation roller has stopped on the hot material roller has turned or roller speed has been changed too quickly incorrect roller operation incorrect foundation preparation truck brake is applied t...

Page 178: ...he material screed extendable parts are incorrectly installed limit switch is not correctly set cold screed bottom plates are worn or warped paver speed is too high Layer composition is not uniform temperature of the material change in the material temperature moisture on the foundation segregation wrong material composition incorrectly prepared foundation wrong layer height for the maximum stone ...

Page 179: ...d vibration is too high while standing in one spot Screed does not react to corrective measures as expected temperature of the material change in the material temperature wrong layer height for maximum grain size incorrect installation of the grade control vibration is too slow screed does not work in the floating position too much play in the mechanical screed link paver speed is too high ...

Page 180: ...or augers run too slowly Hydraulic oil level in the tank is too low Fill with oil Power supply is interrupted Check fuses and cables replace if necessary Sensor is defective Replace the sensor One of the pressure limiting valves is defective Repair or replace the valves Pump shaft broken Replace the pump Limit sensor does not regu late correctly Check the sensor replace the sensor if necessary Pum...

Page 181: ...pted Check fuse and cables replace if necessary Lifting Arms cannot be lifted or lowered Check to see if the switch on the remote control is set to auto Set the switch to manual Power supply is interrupted Check fuse and cables replace if necessary Switch on the operating panel defective Replace Excess pressure valve defective Replace Flow rate regulator defec tive Replace Seals defective Replace ...

Page 182: ...t Insufficient supply pressure Check and adjust if necessary Check the suction filter replace the supply pump and the filter if necessary Drive shaft at hydraulic pumps or engine is broken Replace pump or engine Irregular engine speed engine stop function does not work Fuel level too low Check the fuel level refill fuel if necessary Fuse for engine speed control defective Replace fuse strip on the...

Page 183: ...ts e g screed or hopper against lowering by means of mechanical supports Replace parts or have them replaced as required When connecting or disconnecting hydraulic hoses and when working on the hydraulic system hot hydraulic fluid can escape at a high pressure Switch the engine off and de pressurize the hydraulic system Protect your eyes Mount all protective and safety devices before re commission...

Page 184: ... too high Too much material in front of the screed material overflow When operating with larger widths segregation and traction problems may occur Auger too low Not enough material that can be pre compacted by the auger Irregularities resulting from this cannot be completely compensated for by the screed wavy surface In addition an increased wear on the auger segments occurs 2 2 Auger crossbeam Hy...

Page 185: ...ension chart To attain the desired working width the respective screed extensions side plates augers tunnel plates or cut off shoes must be mounted For widths of more than 11 5 ft 3 5 m the auger should be fitted with extension parts on both sides to improve material distribution and to reduce the wear The diesel engine must be switched off whenever work is performed on the auger as there is a dan...

Page 186: ...severe injury or death as well as damage to the machine 7 6 5 Loosen the clamping screws 6 on the support tube Then turn in the center expanding screw 5 to expand the clamping Pull the telescopic tube out of the support tube 7 Mount the required extension parts NOTE Observe the guide groove of the spline Make sure that the shaft end is clean Install auger so pick end of auger is IN TIME with the d...

Page 187: ... installing the hoses make sure that the area around the connections is clean Any contaminants that enter the hydraulic system can cause damage to the hydraulic system If the working width exceeds 23 ft 7 01 m an auger crossbeam extension must be mounted The support tube extension of the auger cross beam consists of two halves 8 and is attached to the existing support tube by using a total of 5 sc...

Page 188: ...terial When operating with widths of more than 14 4 ft 4 4 m two or more combined tunnel plates 13 must be used In this case additional stabilizing supports 12 must be attached to the telescopic tube The tunnel plates must be directly screwed to the receptacles provided for this purpose 14 they are located on the auger frame sides and can be adjusted in height Refer to the auger extension chart to...

Page 189: ... ft 7 62 m the augers must be provided with an additional support To do so attach two braces on both the left hand and the right hand side between the tunnel plate support and the bracket provided on the paver The braces are included in the scope of delivery for this working width ...

Page 190: ... The screed plugs into the back of the paver socket 15 The paver and the screed communicate through this connection 15 The conveyor sensor connects to the DC control box The control box is connected to the right re mote by a cable through the rear bulkhead The remote then sends the signal from the sensor to the paver thru the cable shown The auger sensor connects to the DC control box The control ...

Page 191: ...to the right re mote by a cable through the rear bulkhead The remote then sends the signal from the sensor to the paver thru the cable shown The auger sensor connects to the DC control box The control box is connected to the right remote by a cable through the rear bulkhead The re mote then sends the signal from the sensor to the paver thru the cable shown ...

Page 192: ...te Support for tunnel extensions Hydr Hose as required 1 2 3 1 2 11 4 in 290 mm 17 0 in 434 mm 34 1 in 866 mm 11 75 in 298 mm 19 75 in 502 mm 1 1 3 11 4 in 289 6 mm 1 1 3 17 0 in 431 8 mm 2 1 1 3 22 8 in 579 1 mm 1 1 1 1 3 28 4 in 721 4 mm 1 2 1 3 34 1 in 866 1 mm 1 1 1 2 1 3 45 5 in 1155 7 mm ...

Page 193: ...E 11 ...

Page 194: ...proved parts and install them according to the specifications If no doubt contact the manufacturer Re commissioning Mount all protective devices before re commissioning the paver Cleaning Cleaning must not be carried out while the engine is running Do not use any flammable substances such as gasoline or diesel fuel Avoid directly cleaning electrical parts and insulation material with a steam jet c...

Page 195: ...F 2 F 2 0 Maintenance overview 1 Maintenance overview ...

Page 196: ...ing service hours 10 50 100 250 500 1000 annually 2000 every 2 years 5000 20000 If necessary Conveyor and Hopper F3 0 Auger F4 0 Engine F5 0 Hydraulics F6 0 Track F7 0 Electronics F8 0 Lubrication points F9 0 Checking decommissioning F10 0 Maintenance required ...

Page 197: ...F 4 F 3 0 Maintenance Conveyor and Hopper 1 Maintenance Conveyor and hopper ...

Page 198: ...rease zert 3 Conveyor bearing Lubricate grease zert 4 Conveyor drive bearings Lubricate grease zert 5 Conveyor drive drive chains Check chain tension Conveyor drive drive chains Set chain tension 6 Conveyor drive planetary gear Oil level check Conveyor drive planetary gear Fill with oil Conveyor drive planetary gear Oil change indicates initial break in period 7 Check conveyor chain guards conveyo...

Page 199: ...ours of operation and before adjusting the tension 11 in 11 in With the paver resting on a level surface the sag of both portions should be a minimum of 11 inches Checking the chain tension The chains should not be too tight or too slack If the chain is too tight material between the chain and the sprocket wheel can lead to stoppage or breakage If the chain is too slack it may get stuck in the pro...

Page 200: ...d always be re placed in sets Conveyor chain Conveyor chain guards Conveyor chain tensioning sprockets Conveyor gear drive sprockets Contact your Dynapac customer service representative for support during maintenance repair and the replacement of worn parts A Chain links must not be removed to shorten the chain Shortening the chains would lead to the destruction of the drive sprockets Adjust the t...

Page 201: ... sprocket bearings for the conveyors are lubricated at the grease zerts A located behind the crossbeam The center conveyor bearing block is lubricated with the grease zert B located inside the rear crossbeam r h side Pump 5 strokes of grease with a grease gun The conveyor drive bearings are lubricated with grease zerts C located inside the front and rear crossbeam r h and l h side Pump 5 strokes o...

Page 202: ...In normal conditions the chain has to have approximately 4 to 6 inch 10 15 mm of play To set the chain tension Loosen the locking bolts A and the lock nut B Set the necessary chain tension with the tension screw C Tighten the locking bolts A and lock nut B again ...

Page 203: ...o add oil Check oil at oil level site glass A Fill with oil of the correct specification through port B until the oil level reaches the middle of the oil level site glass A Use only recommended oil Oil change NOTE Change the oil when the engine is at operating temperature Remove the filling plug B and the drain plug C Drain the oil Return plug C Fill oil through the filling port until the oil leve...

Page 204: ...ive for support during maintenance repair and the replacement of worn parts NOTE When the lower edges of the conveyor chain guards A are worn or reveal holes they must be replaced The conveyor chain is not protected when the conveyor chain guards are worn Remove conveyor chain guard bolts Remove the conveyor chain guards from the material tunnel Install new conveyor chain guards with new bolts NOT...

Page 205: ...F 12 F 4 0 Maintenance Auger 1 Maintenance Auger ...

Page 206: ...r bearing Lubrication 2 Auger central bearing Lubrication 3 Auger drive neck bearing Lubrication 4 Auger bevel gear oil level check Auger bevel gear topping up the oil Auger bevel gear oil change 5 Auger wear plates auger segments Check wear Auger wear plates auger segments Replace auger blade Maintenance Maintenance during run in period ...

Page 207: ...work is finished The outer bearings of the auger must be lubricated when hot so that the eventual bitumen residue is expelled Pump 5 strokes of grease with grease gun The central bearing A is lubricated on the LH side of the auger To do so slide the bevel gear out The central bearing A is lubricated when hot so that the eventual residue is expelled Pump 5 strokes of grease with grease gun ...

Page 208: ...the neck of the drive Replace the plug under it with an extended grease zert 10 x 1 Use a grease gun to pump about 10 strokes of grease Next unscrew the grease zert and screw back in both plugs The neck of the drive is sealed downloads and is lubricated with grease gun ...

Page 209: ...dd the proper oil through port A until the oil level reaches the power edge of the inspection hole A Use only approved oil Replace the inspection filling plug A To change the oil NOTE Change the oil when the engine is at operating temperature Remove the inspection filling plug A and the drain plug B Drain the oil Return the oil drain plug B and tighten Fill oil using an approved fluid through the ...

Page 210: ...d and the blades B have to be replaced C A B E D Remove the bolts C nuts E and auger blade B Sharp edged parts can cause personal injury Auger blades must be installed without any play and the contact surfaces must be dirt free Install the new auger blade B replace the bolts C washers D and nuts E if necessary ...

Page 211: ...F 18 F 5 0 Maintenance Engine 1 Maintenance engine sub unit ...

Page 212: ...0 1000 year 2000 2 years as required 1 Fuel tank Check the filling level Fuel tank Refill with fuel Fuel tank Clean the tank 2 Engine oil system Check oil level Engine oil system Fill with oil Engine lube oil system Change the oil Engine lube oil system Oil filter change 3 Engine fuel system Fuel filter drain the water separator Engine fuel system Replace the fuel pre filter Engine fuel system Rep...

Page 213: ...oling system Inspection the radiator fins Engine cooling system Clean the radiator fins Engine cooling system Check the level of the coolant Engine cooling system Fill with coolant Engine cooling system Changing the coolant Engine cooling system Check coolant level additive concentration 6 Engine drive belt Checking of drive belt Engine drive belt Tightening the drive belt Engine drive belt Replac...

Page 214: ...l on the operating panel check display To add fuel Unscrew cap A under tank covers r h paver side Fill with fuel through the filler neck until the tank is full Replace the cap A Repeat the process for the other tank Cleaning the fuel tanks Unscrew the plug B at the bottom of the tank and drain about 1 qt 1 L of fuel into an environmentally safe collection pan After draining add a new seal ring to ...

Page 215: ...onal injury avoid direct contact of hot oil with your skin Engine lube oil system 2 Check oil level Check that the oil level is between the maximum and minimum lines on the dipstick A NOTE Check the oil level with the paver parked on a flat surface If there is too much oil in the engine the gaskets and seals may become damaged while too little oil can lead to the oil overheating and damage to the ...

Page 216: ...ion onto the engine Lack of engine lubrication while the filter s are pumped full of oil is harmful to the engine There is a drain hose stored behind the left hand side flap Place the end of the hose into a pan to catch the oil Remove the oil drain port plug C and let the oil drain Return the plug Remove the oil cap B and add only approved oil until the oil level reaches the full mark on the dipst...

Page 217: ...in Change the pre filter Drain the separated water at the tap C collect it then close the tap again Remove the water detection indicator connection D Loosen the filter cartridge E using an oil filter wrench or oil filter strap and remove it Clean the sealing surface where the new filter will mount Apply a thin coat of oil to the gasket of the collection sump mount it under the filter cartridge and...

Page 218: ...inated Contaminated fuel will cause accelerated wear to the fuel system parts Main filter replacement Loosen the filter A and clean the surface where the new filter will mount Apply a thin coat of oil to the gasket of the new filter Tighten the filter by hand NOTE After mounting the filter check it for proper tightness ...

Page 219: ...hat should only be replaced and not cleaned The assembly also includes a dust vacuator valve and an air cleaner indicator NOTE Air intake filter pollution depends on the dust con tent in the air and the mesh size of the filter selected The maintenance of the filter becomes necessary if The restriction gauge reads 25 H2O when the engine is stopped This indicates that a restriction has occurred This...

Page 220: ...ear Blow out with dry pressure air max 30 psi 2 07 bar from inside blowing out In case of urgency tap the cartridge to remove dust Check the filter s paper of the filter cartridge by exposing to light and inspect the seals Replace them as required After completing the maintenance Press the reset button F for the maintenance indicator if equipped The maintenance indicator is ready for operation ...

Page 221: ...e must be mixed with quality water at a 50 50 ratio A 50 50 mixture of water and ethylene glycol or propylene glycol antifreeze to fill the cooling system The 50 50 mix gives protection to the cooling system at a range of 34_F 36_C freezing point and a 228_F 110_C boiling point which is adequate for locations in North America The actual lowest freezing point of ethylene glycol antifreeze is 68 per...

Page 222: ... 50 mix of water and ethylene glycol or propylene glycol antifreeze Install the radiator cap Start the engine and allow it to run a few minutes While the engine is running check the radiator and hoses for leaks When the engine coolant temperature reaches about 180 F 80 C turn the engine off and check the coolant level again Checking and cleaning of the radiator fins If necessary remove leaves asph...

Page 223: ...procedures Engine drive belt 6 Check drive belt replacement Under normal operating conditions the engine drive belt s should be inspected daily Belt dam age can be caused by incorrect size or length pulley misalignment incorrect installation severe operating environment and oil or grease on the belt s Adjust the belt tension in order to minimize belt slippage Belt slippage will decrease the life o...

Page 224: ...ensor foot angled upward place the filter edge and the toe of the Tri Function Sensor into the tank bore Gradually work the bottom portion of the DEF head into the Bore opening until completely inserted in the tank Position the DEF head unit in the desired orientation and press on the top of the blue MFHU Removal Using a T25 Torx Driver unscrew the retention screws that secure the Retaining Ring t...

Page 225: ...rom the clips Inspect the new Tri Function Sensor for signs of damage Verify an O Ring is located below the threading at the top of the sensor and should have Parker O Ring Lubrication applied Feed the new Tri Function Sensor cable into the bottom of the mounting base through the sensor opening Press the Tri Function Sensor into the retention clip with the foot of the sensor parallel with the Filt...

Page 226: ...F 31 F 6 0 Maintenance Hydraulic System 1 Maintenance hydraulic system ...

Page 227: ...Hydraulic oil tank Check the maintenance indicator Hydraulic oil tank Intake return Change the hydraulic filter 3 High pressure filter Check the maintenance indicator High pressure filter Replace the filter cartridge 4 Pump distribution gear Check the oil level Pump distribution gear Fill with oil Pump distribution gear Oil change 5 Hydraulic hoses Inspect hoses Hydraulic hoses Replace the hoses M...

Page 228: ...ystem fails is disconnected or is asignaled to cause movement It must also be recognized that there are occasions where component and or vehicle movement may react to the release of potential energy Where applicable it must be confirmed that all measures are employed to ensure that any and all sources of potential energy are released and or physically restrained All tramming hopper and conveyor fu...

Page 229: ...heck at the sight level gauge A on the side of the tank NOTE View the sight level gauge by the opening tank flap on the L H side of the machine With the cylinders fully retracted the oil level should at the upper mark To add oil Remove cap B Add oil through the fill port until the level shows full at the sight level gauge A Return cap B NOTE ...

Page 230: ...st be filled with fresh clean oil Always change the hydraulic oil filter s when changing the hydraulic oil To change the oil To drain the hydraulic oil unscrew the drain plug C at the bottom of the tank Collect the oil in an appropriate container using a funnel After draining add a new seal ring and then screw the plug back into place ...

Page 231: ... oil must be at least 175 F 80 C When changing the hydraulic oil also change the filter Remove the lid fastening screws B and remove the lid Disassemble the withdrawn unit into the following parts Lid C Separating plate D Filter E Dirt collection cage F Clean the filter case the lid the separating plate and the dirt collection cage Check and replace the O rings G when required Wet the seal surface...

Page 232: ...he housing and tighten the locking screws of the lid B Open the vent screw H Mount a transparent hose l on the vent screw and lead it into an appropriate container Start the engine and run it at idle speed Shut off the bleeding screw H as soon as the oil discharged through the hose is clean and free of air bubbles The process from mounting the filter lid until starting the engine should take place...

Page 233: ...e the auger charge filter A cartridge and conveyor pump work system filter B when the maintenance indicator on top of the filter cartridge head turns red Unscrew filter housing Remove the filter cartridge Clean the filter housing Insert the new filter cartridge Replace the seal O ring on the filter housing Screw the filter housing on by hand then tighten it using the appropriate tool Test the filt...

Page 234: ...l or components Gearbox must be filled with fresh clean oil Pump distribution gear 4 Check the oil level at the sight glass A at the side of the distribution box NOTE The oil level must be up to the center of the sight glass To add oil Unscrew the plug B Add oil until the sight glass A shows the correct fluid level Return and tighten the plug B ...

Page 235: ...he oil when the engine is at operating temperature Place the end of the hose in an appropriate container and catch the oil Open the shut off valve and let the oil drain completely Shut off the valve remove the hose and return the cover cap Add only approved oil to the distribution box B until the oil level is at the center of the sight glass A ...

Page 236: ...ose has the maximum pressure allowed for that hose printed on it Do not use hoses that have been in storage for a long time Check for the proper pressure rating printed on the hose Hydraulic hoses 5 Frayed or damaged hoses can break instantly causing hot hydraulic fluid to spray causing severe burns Always replace worn or damage hoses immediately Check the condition of the hydraulic hoses carefull...

Page 237: ...F 42 F 7 0 Maintenance Track 1 Maintenance running gear ...

Page 238: ...de rollers drive wheels En sure proper torque for bolts 2 Guide rollers check straight running Guide rollers straight running setting Guide rollers ensure the adjusting bolts are tight Guide rollers tighten the adjusting bolts 3 Planetary gear Check the oil level Planetary gear fill with oil Planetary gear oil change 4 Gear guide rollers front Grease them Maintenance Maintenance during run in peri...

Page 239: ...t a thin layer of this material on the driven surface of the drive wheel idler or roller and turn on the drive for a very short period This serves to remove the sticky layer and provides optimal biting for the gear and the drive wheel idler and rollers Pre treatment of these parts is necessary only when they are new The wheels idlers or guide rollers should not come into contact with grease oil be...

Page 240: ...e machine must be stored outdoors please cover the tracks drive wheels idlers and guide rollers with non transparent canvas Avoid excessive humidity Longer contact with water may attack the drive wheels idlers or guide rollers Do not store the machine in standing water The machine must be stored under a roof or in a protected area whenever it is possible If the machine must be stored outdoors plea...

Page 241: ... values Guide rollers A 12 rollers 105 ft lbs 142 4 Nm Idlers B 2 idlers 314 ft lbs 425 7 Nm In addition to this all mounting bolts on the drive wheel C should be checked and re torqued if necessary Drive wheels 2 drive wheels 375 ft lbs 508 4 Nm Mounting bolts for all idlers guide rollers and drives should be checked and tightened if necessary ...

Page 242: ...basis Move the machine forward and backward to check if the rollers are running straight The rollers running straight is very important and directly affects their life cycle Guide rollers straight running secure the adjustment bolts 2 The adjustment bolts are located in the front part of the drives and at the regulator links of the guide rollers If the wheels and rollers run outwards or inwards or...

Page 243: ...suitable containers before opening any compartment or disassembling any component containing fluids Dispose of fluids according to local regulations and mandate Position the planetary gearbox so that the oil drain B is vertical at its lowest point about the 6 o clock position The oil filler plug A should then be on the Left or Right outside of the planetary middle Clean the area around the check p...

Page 244: ...ess on the undercarriage while wasting horsepower and causing higher fuel consumption Check the drive idler bearing A for wear and ensure they are filled with grease To re grease the idler bearings Remove protective cap B Clean any used grease from the bearing assembly A and replace the old grease with the proper amount of new grease by packing the grease into the bearing Return protective cap B ...

Page 245: ...or the equivalent quality lubricants Use only clean containers for adding oil or fuel Take into account the filling volumes see the section Filling volumes Low quality oil or lubricant causes faster wear and the failure of the machine Mixing of synthetic and natural oils is explicitly prohibited ...

Page 246: ...F 51 F 8 0 Maintenance Electronic System 1 Maintenance Electronic system ...

Page 247: ... Maintenance point Note 10 50 100 250 500 1000 annually 5000 20000 If necessary 1 Check the charge level of the batteries replace if necessary Apply grease to battery terminals 3 Electric fuses Maintenance Maintenance during the running in period ...

Page 248: ...e protective glasses when working with batteries Never disconnect any charging unit circuit or battery circuit cable from the battery when charging unit is operating A spark can cause explosions The batteries equipped with the paver are Maintenance Free batteries When batteries can no longer hold a charge they must be replaced The battery terminal clips must be free of corrosion oxide and protecte...

Page 249: ...F 54 Electric fuses relays 3 Main fuses A Fuse Description Rating A F1 Main Battery 100 F2 Alternator 100 F3 Switch Power From Key 50 F4 Air Heater Power Supply 125 F7 ECM Power Supply 30 ...

Page 250: ...ay Hour Meter 10 F13 Proper Devices 10 F14 Console Select Switch and Parking Brake 5 F15 Auger Conveyor On Off and Auto Manual Switch 5 F17 Auger Raise Lower Ext Ret 10 F18 Tow Arm Levelling Control 10 F19 Screed Raise Lower Ext Ret 10 F20 Vibration Solenoid 2 F22 Work Lights 10 F23 Dash Board Lamp 5 F24 DC 24 V Outlet Front 10 F25 DC 24 V Outlet Front 10 F26 DC 24 V Outlet Rear 10 F27 DC 24 V Out...

Page 251: ...ch Hitch and Wash Down 10 F32 Screed Power Supply 15 F33 Screed Power Supply 15 F34 Front Wheel Assist 3 F35 Auger Conveyor Controller Power Supply 10 F36 Auger Conveyor Cleaning Fast Fill Switch 10 F37 Auger Conveyor Ultrasonic Sensor 5 F38 Auger Conveyor Override Switch Power 10 ...

Page 252: ...ater K5 Auger Conveyor ON OFF K7 Auto Mode Enable Screed Float Vibration Leveling K8 Left Conveyor OFF K9 Right Conveyor OFF K10 Starter Lock Out K11 Screed Float Lock K12 Console Select Indication K13 Left Auger OFF K14 Right Auger OFF K15 Key Switch Power K16 Flasher Warning Turning Signal K17 Flasher Warning Turning Signal ...

Page 253: ... points NOTE The information on the lubrication points for the various assemblies is assigned to the specific maintenance descriptions I E grease points for the auger are in the auger section and grease points for the undercarriage are in the section on undercarriages ...

Page 254: ...F 59 1 1 Maintenance intervals Item Interval Maintenance point Note 10 50 100 250 500 1000 annually 5000 20000 If necessary 1 Bearing points Maintenance Maintenance during the break in period ...

Page 255: ...F 60 1 2 Points of maintenance Bearing points 1 One grease zert A is located at each hydraulic cylinder bearing point top and bottom ...

Page 256: ...F 61 F 10 0 Checks Decommissioning 1 Tests check up cleaning stopping ...

Page 257: ...No Interval Points of maintenance Remark 10 50 100 250 500 1000 year 2000 2 years as required 1 General observation 2 Checked by a specialist 3 Cleaning 4 Preservation for storage of paver Maintenance Maintenance during run in period ...

Page 258: ...nts secure conveyor auger screed Repair the damages and clean any spills immediately to avoid risks of accidents and environmental pollution 3 Check performed by a specialist The paver the screed and the electrical equipment MUST be checked regularly by a specialist As required according to the circumstances of application and operating conditions However at least once a year so that the machine r...

Page 259: ...after laying material mixes lean concrete etc Remove all residue of the material laid Do not spray water on the bearings electric or electronic parts Remove the residue of the material laid After cleaning with the high pressure jet lubricate all of the bearings with grease as specified Slippery walkways and steps can result in severe or deadly slipping and failing Ensure the cleanliness of the wal...

Page 260: ...l surfaces i e hydraulic cylinder piston rods against ing an appropriate agent corrosion us If the machine cannot be parked in a garage barn or a shed it must be covered with an appropriate canvas In each case all the air inlets and outlets must be tightly sealed using plastic film and adhesive tape 5 2 Downtime between 6 months and 1 year Perform all operations described for Downtime up to 6 mont...

Page 261: ...must be carried out after replacing wear and spare parts and after the machine has been withdrawn from service scrapped The materials must be sorted correctly according to metal plastic electronic scrap various operating substances etc Any oily or greasy parts hydraulic hoses lube pipes etc must be treated separately Electric devices accessories and packaging should be recycled in an environment f...

Page 262: ...the lubricants listed below or their equivalents Only use clean containers for filling oil or fuel Follow to the correct filling volumes see the section Capacities Incorrect oil or lubricant levels increase the wear and cause the paver to fail Never mix synthetic oils with mineral oils F 67 ...

Page 263: ...0L 4812008276 209L 5 Bonfig Drive Left Fluid Gearbox 100 Environment degree between 20 30 0 8 gal 3 0 L 4812008274 5L 4812008275 20L 4812008276 209L 6 Bonfig Drive Right Fluid Gearbox 100 Environment degree between 20 30 7 Pump Drive Gearbox Fluid Gearbox 100 Environment degree between 20 30 1 4 gal 5 3 L 4812008274 5L 4812008275 20L 4812008276 209L 8 Auger Gearbox Left Fluid Gearbox 100 Environme...