Atlas Copco Dynapac F1000W T4i Operation & Maintenance Manual Download Page 172

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F 3.0 2

F_3.0_0

1_US.

fm 2-

1.1

Maintenance intervals

No.

Interval

Points of maintenance

Remark

/ y

ars

as required

Checking the tension of the conveyor chain

Adjusting the tension of the conveyor chain

Conveyor chain - Check chain

Conveyor chain - Replace chain

Clean Conveyor chain supports

Conveyor tensioning sprocket -

Lubricate grease zert

Conveyor bearing -

Lubricate grease zert

Conveyor drive bearings -

Lubricate grease zert

Conveyor drive / drive chains

Check chain tension

Conveyor drive / drive chains

Set chain tension

Conveyor drive - planetary gear

Oil level check

Conveyor drive - planetary gear

Fill with oil

Conveyor drive - planetary gear

Oil change (

indicates initial break-in pe-

riod)

Check conveyor chain guards, conveyor

plates

Replace conveyor chain guards, conveyor

plates

Hopper cylinders - Lubricate grease zerts

Maintenance

Maintenance during break-in period

Summary of Contents for Dynapac F1000W T4i

Page 1: ...F1000W T4i Edit 2 Mar 2016 D717410129 A4 4812247566 A5 OPERATION MAINTENANCE Paver Finisher EN Keep for later use in document compartment Valid for...

Page 2: ...www atlascopco com...

Page 3: ...le 8 4 4 Turning circle 8 4 5 Weights F1000W 9 4 6 Performance data 9 4 7 Traction drive chassis 10 4 8 Engine 10 4 9 Hydraulic systemOperator stations 10 4 10 Electrical system 10 4 11 Operator stati...

Page 4: ...tion using Soft Keys 2 Brightness Contrast Adjustment 3 Main Menu Start Menu 3 Main Menu Basic Setup 4 Main Menu Basic Setup Time Date 5 Main Menu Basic Setup Language 5 Main Menu Basic Setup Units 6...

Page 5: ...s 24V 8 D4 0 Operation 1 1 Preparation of operation 1 Required equipment and tools 1 Before starting work in the morning or when starting paving 2 Checklist for the machine operator 2 1 1 Starting the...

Page 6: ...ol 8 4 3 Right hand auger sensor control 8 4 4 Left hand conveyor sensor control 9 4 5 Left hand auger sensor control 9 4 6 Auger Chart 10 F1 0 Maintenance 1 1 Notes regarding safety 1 F2 1 Maintenanc...

Page 7: ...1 4 Suction return flow hydraulic filter 2 6 Venting the filter 7 High pressure filter 3 8 Pump distribution gear 4 9 Hydraulic hoses 5 11 F7 1 Maintenance Travel Drive Steering 1 1 Maintenance travel...

Page 8: ...vals 2 2 General observation 3 3 Check performed by a specialist 3 4 Cleaning 4 5 Preservation for storage of paver 5 5 1 Downtime up to 6 months 5 5 2 Downtime between 6 months and 1 year 5 5 3 Re co...

Page 9: ...property damage if the warning is ignored Warning is used to indicate the presence of a hazard which can cause severe personal injury death or extensive property damage if the warning is ignored Cauti...

Page 10: ...V 2 V_01_US fm Dynapac China Compaction Paving Equipment Co Ltd No 38 Quanwang Road Wuqing High Tech Industrial Park 301700 Tianjin China www dynapac com...

Page 11: ...ecting any part of a paving machine it is important that the individual knows how the components move and are controlled by the hydraulic system compo nents including the respective control circuits B...

Page 12: ...witched off Attention electric voltage All maintenance and repair work on the screed s electrical system must always be carried out by an electrician Attention suspended load Never stand under suspend...

Page 13: ...vere injury or death Caution hazardous batteries Combustible gas can cause severe burns blindness or death Keep sparks and open flame away from batteries Caution materials harmful to health and irrita...

Page 14: ...engine drive Maintenance and repair can be carried out only with the Diesel en gine turned off Do not spray with water Do not extinguish with water Unskilled maintenance is prohibited Maintenance can...

Page 15: ...Observe these specifications Protect your eyes with goggles Wear appropriate head protection Protect your hearing with appropriate ear mufflers Protect your feet with safety footwear Always wear tight...

Page 16: ...utants such as lubricants oils grease hydraulic oil gas oil coolant detergents may not enter the soil or the sewer system These materials shall be collected stored transported in the correct container...

Page 17: ...1 7 Further instructions Observe the manufacturer s and other instructions i e the maintenance instructions from the engine manufacturer Indicates a bottled gas heated design indicates an electrically...

Page 18: ...V 10 V_01_US fm...

Page 19: ...A 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 o...

Page 20: ......

Page 21: ...ription 1 Application The Dynapac F1000W is a rubber tire fitted paver finisher that is used for laying bituminous mixed ma terial roll down or lean mixed concrete track laying ballast and unbound min...

Page 22: ...tandem axle 7 Standard Rear wheels 8 Standard Levelling cylinder for paving thickness 9 Standard Traction arm guide 10 Standard Traction roller 11 Standard Screed lifing arm 12 Standard Auger 13 Stand...

Page 23: ...on drive allows the speed of the paver to be matched to all work conditions The operation of the paver includes the automatic material handling system the in dependent travel drives and the clearly st...

Page 24: ...aulic sys tem also drives the generator needed to heat materials to prevent the material from sticking to the screed plate All power on the paver comes from hydraulics Propel drive The closed loop pro...

Page 25: ...ustment and extension of augers ensure an optimum variety of a wide range of paving thicknesses and widths Auger height is regulated at the operating panel and moved by means of hydraulic cylinders Au...

Page 26: ...he machine marked in red there may be a risk of pulling in or crushing during normal operation caused by rotating and conveying elements or by components in motion The Danger Zones for the paver are i...

Page 27: ...ration 4 1 Dimensions all dimensions in inches Carlson EZ IV 78 87 in 200 3 cm 282 76 in 718 2 cm 36 42 in 92 5 cm 236 42 in 92 5 cm 107 48 in 273 cm 81 49 in 207 cm 133 9 in 340 1 cm 63 41 in 161 1 c...

Page 28: ...n 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 4 4 Tu...

Page 29: ...ditional maximum of approx 30400 lbs 13608 kg Screed used Basic width without cut off shoes Minimum paving width with cut off shoe Continuously hydraulically adjustable up to Maximum working widths wi...

Page 30: ...mins QSB 6 7 Tier IV Interim Version 6 cylinder diesel engine water cooled Performance 230 hp 1800rpm 220 hp 2000rpm Fuel tank capacity 2 tanks 49 Gal 185 lt each Hydraulic pressure supply source Hydr...

Page 31: ...cants and operating substances see chapter F Control consoles Dual swing out operation stations Volume approx 207ft3 5 86m3 Minimum inlet height center 38 5 in 978mm Conveyor type Dual independent sla...

Page 32: ...B 12 B_F1000W_US fm 12 18 5 Location of instruction labels and identification plates 1 2 5 8 4 6 7 15 10 12 5 6 Manuals are located behind operator seat 14 6 3 9...

Page 33: ...y Manual Failure to follow the in structions 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 W...

Page 34: ...faces can cause burns or per sonal injury Do not come into contact with hot parts or components Wear protective clothing or protective equip ment 10 Wear ear protection when using the machine Hearing...

Page 35: ...s running or moving Do not work in this area when the machine turns or ma chine parts move Crushing can cause severe injury or death Item Decal Description Item Designation 1 Paver type 2 Operating Ma...

Page 36: ...operating mass rated power and the year of manufacture The stamped vehicle identification number on the paver must match the product identification number Identification plate for the paver finisher...

Page 37: ...ns according to the EN 500 6 draft dated March 1997 and ISO 4872 Sound pressure level at the operator s position at the height of the head LH Console RH Console LAF 84 4 dB A 85 9 dB A Sound capacity...

Page 38: ...ispherical measuring surface with a radius of 16 m The machine was at the centre The measuring points had been assigned the following coordinates Measuring points 2 4 6 8 Measuring points 10 12 Co ord...

Page 39: ...equipped and engage the latch Check that the clamping device for the auger crossbeam is fastened and that the tel escopic tube cannot slide out see chapter E section 2 5 Pack all parts that are not pe...

Page 40: ...nd 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...

Page 41: ...n driving on an incline Attachment and loading equipment must meet the federal state and local safety reg ulations The weight of the paver finisher must be taken into consideration when selecting the...

Page 42: ...4 C_1 1_01_US fm 4 16 Transport on Low Bed Trailers 1 7 10 4 11 5 8 2 9 12...

Page 43: ...the screed 5 Retract the screed to the basic width of the paver 6 Engage both screed transport safeguards 7 Lift the auger 8 Turn the range shift selector to zero 9 Turn the travel speed preselecting...

Page 44: ...onto wooden 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 finisher to the low bed trailer Use only proper...

Page 45: ...wing 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 a...

Page 46: ...d to their 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 paver and screed see also Ope...

Page 47: ...9 C_1 1_01_US fm 9 16 Transport Preparation 7 4 5 11 9 2 8 10 1 12...

Page 48: ...screed 5 Retract the screed to the basic width of the paver finisher 6 Engage both screed transport safeguards 7 Lift the auger 8 Turn the range shift selector to zero 9 Turn the travel speed presele...

Page 49: ...11 C_1 1_01_US fm 11 16 3 2 Driving mode 3 1 2...

Page 50: ...2 16 Press the emergency stop button when a dangerous situation arises Item Operation 1 Turn the selector to position 3 2 Turn the preselecting regulator to its maxi mum point 3 Use the drive lever to...

Page 51: ...e acci dent 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 Depending on the type of s...

Page 52: ...e parts see chapters E and D 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 1...

Page 53: ...olling or is already properly connected to the towing vehicle Attach the towing device to the tie down points located in the bumper under the hopper Push down and turn the Pump Pressure Lock and Relea...

Page 54: ...switch 1 and take it with you do not hide them some where on the machine Protect the operating panel with the dust cover and lock it Store loose parts and accessories in a safe place 1 Do not turn th...

Page 55: ...and limb Always 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...

Page 56: ...D 1 1 2 D_1 1_01_US fm 2 44 2 Controls 2 1 Operating panel 2 E 1 A B C D 3 2 3 1 C D B A Left Hand Operator s Panel Right Hand Operator s Panel 2 E...

Page 57: ...of the two 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 swi...

Page 58: ...D 1 1 4 D_1 1_01_US fm 4 44 PANEL A 10 14 11 12 15 14 11 12 15 Right Hand Operator s Panel Left Hand Operator s Panel...

Page 59: ...lever is at its stop NOTE The speed level is preset with the Travel drive engine pre selector switch 14 Truck hitch Opening and closing the truck hitch device at the front of the paver Toggle switch f...

Page 60: ...D 1 1 6 D_1 1_01_US fm 6 44 PANEL B 28 30 29 22 23 21 25 26 27 26 21 22 30 20 20 Left Hand Operator s Panel Right Hand Operator s Panel 24...

Page 61: ...operates when the drive lever is out of neutral and in the forward position 21 Preselector switch travel drive engine fast slow To preselect the desired speed level Switch setting 0 Preselected vehicl...

Page 62: ...D 1 1 8 D_1 1_01_US fm 8 44 PANEL B 28 30 29 22 23 21 25 26 27 26 21 22 30 20 20 Left Hand Operator s Panel Right Hand Operator s Panel 24...

Page 63: ...soot levels are high enough to allow regeneration The diesel particulate filter LED lo cated on Panel E will be lit either static or blinking throughout the regeneration process Refer to Item 56 for...

Page 64: ...D 1 1 10 D_1 1_01_US fm 10 44 PANEL B 28 30 29 22 23 21 25 26 27 26 21 22 30 20 20 Left Hand Operator s Panel Right Hand Operator s Panel 24...

Page 65: ...E Speed control see Operating instructions for the screed 29 30 Selector switch left right operating panel 19 active panel LED 20 To select the primary activated operating panel Toggle switch function...

Page 66: ...D 1 1 12 D_1 1_01_US fm 12 44 PANEL C 46 45 47 48 43 44 41 42 40 49...

Page 67: ...away from the 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 Togg...

Page 68: ...D 1 1 14 D_1 1_01_US fm 14 44 PANEL C 46 45 47 48 43 44 41 42 40 49...

Page 69: ...LED Toggles between AUTOMATIC and MANUAL operating modes for the con veyor auger The left switch operates the left auger and conveyor while the right switch oprates the right auger and conveyor Toggl...

Page 70: ...D 1 1 16 D_1 1_01_US fm 16 44 PANEL C 46 45 47 48 43 44 41 42 40 49...

Page 71: ...the switch forward away from the operator Raise auger Toggle the switch back toward the operator Lower auger Toggle both switches raise lower left right auger at the same time to keep the auger crossb...

Page 72: ...D 1 1 18 D_1 1_01_US fm 18 44 PANEL D 53 54 55 51 50 52 53 52 51 50...

Page 73: ...achine 51 Extend retract right screed exten sion Hydraulically retracted and extended the right extendable part of the screed Toggle switch function Toggle the switch left Retract screed extension Tog...

Page 74: ...D 1 1 20 D_1 1_01_US fm 20 44 PANEL D 53 54 55 51 50 52 53 52 51 50...

Page 75: ...ard the operator Lower the screed and switch to floating position During paving the screed must always be in its floating posi tion This also applies to intermediate stops and truck changes As soon as...

Page 76: ...D 1 1 22 D_1 1_01_US fm 22 44 PANEL D 53 54 55 51 50 52 53 52 51 50...

Page 77: ...nd or lower leveling cylinder Do not raise or lower the leveling cylinder until all equipment and persons are clear of the machine 55 Right leveling cylinder To manually extend and retract the levelin...

Page 78: ...D 1 1 24 D_1 1_01_US fm 24 44 PANEL E 56 57 58...

Page 79: ...ration is an extremely hot po cess and could easily ignite combustible materials The diesel particulate filter may require servicing with prolonged use of the regeneration inhibit function If regenera...

Page 80: ...D 1 1 26 D_1 1_01_US fm 26 44 PANEL E 56 57 58...

Page 81: ...an extremely 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...

Page 82: ...D 1 1 28 D_1 1_01_US fm 28 44 3 Auxiliary functions 60 61 63 62...

Page 83: ...ed switch the 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 spraye...

Page 84: ...f the vehicle and various overall functions B RIGHT remote control Controls certain functions on the right hand side of the vehi cle and various overall functions C LEFT handset Removable handset for...

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

Page 86: ...hen no material 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 M...

Page 87: ...01_US fm 33 44 70 80 78 82 71 84 88 90 92 93 94 70 73 75 77 71 87 89 90 91 92 93 95 86 72 74 76 81 79 83 85 The left remote controls the left auger and conveyor The right remote controls the right aug...

Page 88: ...tch right 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 the operator Conveyor OFF...

Page 89: ..._US fm 35 44 70 80 78 82 71 84 88 90 91 93 94 70 73 75 77 71 87 89 90 91 92 93 95 86 72 74 76 81 79 83 85 The left remote controls the left auger and conveyor The right remote controls the right auger...

Page 90: ...t equipment and per sons are clear of the machine 86 Left hydraulic tunnel extention retract op tion Controls the tunnel extension Toggle swtich function Toggle the switch outward away from the screed...

Page 91: ..._US fm 37 44 70 80 78 82 71 84 88 90 91 92 93 94 70 73 75 77 71 87 89 90 91 92 93 95 86 72 74 76 81 79 83 85 The left remote controls the left auger and conveyor The right remote controls the right au...

Page 92: ...erating 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 t...

Page 93: ..._US fm 39 44 70 80 78 82 71 84 88 90 91 92 93 94 70 73 75 77 71 87 89 90 91 92 93 95 86 72 74 76 81 79 83 85 The left remote controls the left auger and conveyor The right remote controls the right au...

Page 94: ...itch right Retract screed extension Before operating the toggle switch ensure that equipment and per sons are clear of the machine 95 Extend retract right screed extension To hydraulically retract and...

Page 95: ...D 1 1 41 D_1 1_01_US fm 41 44 Left right handset 100 102 104 106 101 103 105 107...

Page 96: ...orward away 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 eqipment and per son...

Page 97: ...D 1 1 43 D_1 1_01_US fm 43 44 100 102 104 106 101 103 105 107...

Page 98: ...tendable part of the screed Push button function Toggle switch left Retract screed Toggle switch right Extend screed Before operating the toggle switch ensure that eqipment and per sons are clear of t...

Page 99: ...y for engine information diagnostic information and configuration 2 Softkeys Terminal is controlled by navigation through a set of four soft keys The keys are context dependent Soft key selection opti...

Page 100: ...selection op tions The selection options will be displayed for three seconds Item Designation Brief description 1 Brightness Contrast Press to access brightness and contrast settings 2 Navigate Up Pr...

Page 101: ...brightness and contrast soft key bar The bar will disappear after 3 seconds of inactivity Main Menu Start Menu The Main Menu screen is the starting point for configuring the terminal Basic Setup Use t...

Page 102: ...t time language and display units for the terminal Time Date Use Time Date set date and display style for time and date information Language Use Language to set the system language Units Use Units to...

Page 103: ...set Time Date calendar style and time style Use up down select and next soft keys to navigate Main Menu Basic Setup Language Use Language screen to se lect program language Lan guages available Englis...

Page 104: ...u Basic Setup Units Use the up down select and next soft keys to define unit measurements Speed km h mph Distance km mi Pressure kPa bar Ibs sq in Volume l gal imp gal Temperature C F Fuel Economy 1 1...

Page 105: ...7 D_2 0_01_US fm 7 24 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 term...

Page 106: ...soft ware 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 s...

Page 107: ...ostics Fault Log Active and Previous Faults Selecting Active Faults in the Fault Menu will display all ac tive faults on the CAN net work Selecting Previous Faults in the Fault Menu will display all p...

Page 108: ...nger on the CAN network Fault pop up softkey actions Fault Pop Up Alarms Faults no longer active will also be displayed in the Previous Faults log Faults that have been acknowledged and are no longer...

Page 109: ...D 2 0 11 D_2 0_01_US fm 11 24 Main Menu Diagnostics Device List The Device list page will list all J1939 devices and ad dresses that are currently be ing monitored on the network...

Page 110: ...ngle view display To select signals for display press the far right soft key Quick Data softkey Scroll through signal list using the up and down arrow soft keys and select de select signals for Quick...

Page 111: ...13 D_2 0_01_US fm 13 24 Start Display Appears at system start Model Select Use the scroll buttons to select the appropriate paver movel Once the check mark is on the correct model press OK 1 2 3 4 1...

Page 112: ...2 in rpm with bar chart Diesel tank filling 3 in with bar chart Engine Coolant Temperature 4 in F Display 02 Display menu Hydraulic Oil Tempersature 1 in F Engine Operation Hours 2 in hours Engine Coo...

Page 113: ...Codes Nr Source Nr Source 1 Sensor Power 2 Battery 3 Left Joystick 4 Right Joystick 5 Left Steer Wheel Position Sensor 6 Right Steer Wheel Position Sensor 7 Left Trim Steer POT 8 Right Trim Steer POT...

Page 114: ...owered up 5 Return Joystick to neutral Brake is applied try to stroke joystick 6 Release the brake before driving Change console selector switch while machine in mov ing 7 Change active console when m...

Page 115: ...hort Open 27 Short 26 Conv_PotLH_Open Conv_PotLH_Short RH conveyor potentiometer open short Open 29 Short 30 Conv_PotRH_Open Conv_PotRH_Short LH auger potentiometer open short Open 31 Short 30 AugerPo...

Page 116: ...D 2 0 18 D_2 0_01_US fm 18 24 1 2 Engine Error messages...

Page 117: ...D 2 0 19 D_2 0_01_US fm 19 24...

Page 118: ...D 2 0 20 D_2 0_01_US fm 20 24...

Page 119: ...D 2 0 21 D_2 0_01_US fm 21 24...

Page 120: ...D 2 0 22 D_2 0_01_US fm 22 24...

Page 121: ...D 2 0 23 D_2 0_01_US fm 23 24 1 3 FMI codes...

Page 122: ...D 2 0 24 D_2 0_01_US fm 24 24...

Page 123: ...le providing 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 position...

Page 124: ...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...

Page 125: ...nition off turn the key 1 to the left and pull it out Do not lose the key Without it the paver can no longer be moved 1 1 Do not turn the main switch off until 30 seconds after the ignition has been t...

Page 126: ...nveyor Mechanical screed transport safe guard to the left and the right be neath the driver s seat Used to protect the lifted screed from inadvertent lowering The screed transport safeguard must be in...

Page 127: ...locat ed 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...

Page 128: ...OTE 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...

Page 129: ...e function of the warning beacon must be checked daily before starting work Place the warning beacon onto the plug in con tact and secure with a wing bolt 1 Slide the warning beacon with tube 2 to the...

Page 130: ...limit sensors 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 ca...

Page 131: ...porting heavy 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 th...

Page 132: ...ven be low Checklist for the machine operator Check How Emergency stop button on the operating panel on both remote control units Push in the button The diesel engine and all running drives must stop...

Page 133: ...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 transpo...

Page 134: ...D 4 0 4 D_4 1_01_US fm 4 26 40 20 21 10 12 40 20 21 12...

Page 135: ...ive lever 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 dur...

Page 136: ...D 4 0 6 D_4 1_01_US fm 6 26 40 20 21 10 12 40 20 21 12...

Page 137: ...Set the drive 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 Con...

Page 138: ...D 4 0 8 D_4 1_01_US fm 8 26 40 20 21 10 12 40 20 21 12...

Page 139: ...g To increase 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 pos...

Page 140: ...D 4 0 10 D_4 1_01_US fm 10 26 40 47 48 52 54 55 20 21 10 12 40 47 48 52 20 21 12...

Page 141: ...1 for traction 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...

Page 142: ...Switch the screed heater On for about 15 30 minutes depending on the ambient temperature before paving begins Warming up prevents the material from sticking to the screed plates Direction marks To ens...

Page 143: ...D 4 0 13 D_4 1_01_US fm 13 26 46 45 21 15 45 45 20 21 15 20...

Page 144: ...o position Set the selector 21 for traction drive engine to position 1 and push the drive lever 20 forward away from operator Conveyor and auger will begin to work The limit sensors for the conveyors...

Page 145: ...D 4 0 15 D_4 1_01_US fm 15 26 46 45 53 27 28 20 21 12 46 45 20 21 12 53 24...

Page 146: ...er 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 chai...

Page 147: ...are in the way Uniform material transport and distribution or supply to the screed may require cor rections to settings of the material switches for conveyor and auger NOTE See the section D4 Malfunct...

Page 148: ...D 4 0 18 D_4 1_01_US fm 18 26 45 27 24 20 25 21 28 10 12 45 20 21 12...

Page 149: ...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...

Page 150: ...D 4 0 20 D_4 1_01_US fm 20 26 45 47 48 54 52 55 50 51 27 24 20 25 21 28 10 12 45 48 47 52 54 50 51 20 21 12...

Page 151: ...drop out Switch the ignition 10 off Switch screed heater system off Remove the levelling units and stow them away in their boxes and close the boxes 74 Remove all parts that extend beyond the paver w...

Page 152: ...d 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 operatio...

Page 153: ...loads vibration is too slow screed extendable parts are incorrectly installed cold screed bottom plates are worn or warped screed does not work in the floating position paver speed is too high auger i...

Page 154: ...r Conveyor 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 sen...

Page 155: ...is interrupted 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 suppl...

Page 156: ...e servo unit 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...

Page 157: ...machine parts 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...

Page 158: ...blems Auger 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...

Page 159: ...t Auger extension chart To attain the desired working width the respective screed extensions side plates au gers tunnel plates or cut off shoes must be mounted For widths of more than 11 5 ft 3 5 m th...

Page 160: ...ge or rounded stone to prevent segregation If already mounted and segregation occurs in the mat at extension to main connection move the auger pickup 180 degrees from the current position Slide in the...

Page 161: ...occurs by tightening the screwed connections 9 linking the support tube extension If the working width exceeds 14 ft 6 26 m the hydraulic hoses 10 for the auger motors must be replaced with longer one...

Page 162: ...he material When operating with widths of more than 14 4 ft 4 4 m two or more com bined tunnel plates 13 must be used In this case additional stabilizing sup ports 12 must be attached to the tele scop...

Page 163: ...re than 25 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 pr...

Page 164: ...and the screed communicate through this connection 4 2 Right hand conveyor sensor control The conveyor sensor connects to the DC control box The control box is connected to the right re mote by a cab...

Page 165: ...a cable through the rear bulkhead The remote then sends the signal from the sensor to the paver thru the cable shown 4 5 Left hand auger sensor control The auger sensor connects to the DC control box...

Page 166: ...E 01 10 E_1 0_01_US fm 10 10 4 6 Auger Chart...

Page 167: ...e only approved parts and install them according to the specifica tions If in doubt contact the manufacturer Re commissioning Mount all protective devices before re commissioning the pav er Cleaning C...

Page 168: ...F 1 0 2 F_1 0_01_US fm 2 2...

Page 169: ...1 F_2 1_01_US fm 1 2 F 2 1 Maintenance Overview 1 Maintenance overview 7 1 9 0 10 0 3 0 5 0 8 1 6 0 4...

Page 170: ...00 annually 2000 every 2 years 5000 20000 If necessary Conveyor F3 0 q q q q q q Auger F4 0 q q q q q q Engine F5 0 q q q q q q Hydraulics F6 0 q q q q q q Travel drive steering F7 1 q q q q Electroni...

Page 171: ...F 3 0 1 F_3 0_01_US fm 1 8 F 3 0 Maintenance Conveyor and Hopper 1 Maintenance Conveyor and Hopper 1 2 3 4 5 6 7 1 8...

Page 172: ...grease zert 3 q Conveyor bearing Lubricate grease zert 4 q Conveyor drive bearings Lubricate grease zert 5 q Conveyor drive drive chains Check chain tension q Conveyor drive drive chains Set chain te...

Page 173: ...1000 hours of operation and before adjusting the 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 stoppa...

Page 174: ...ead to the destruc tion of the drive sprockets Adjust the tensioning instead If components have to be replaced as a result of wear the following components should always be re placed in sets Conveyor...

Page 175: ...g grease zerts Pump 5 strokes of grease with a grease gun Conveyor bearing block 1 The center conveyor bearing block is lubricated with the grease zert B located insided the rear crossbeam r h side Pu...

Page 176: ...ension In normal conditions the chain has to have ap proximately 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 wit...

Page 177: ...f the correct specification through port B until the oil level reaches the middle of the oil level site glass A Use only recom mended oil Oil change NOTE Change the oil when the engine is at operating...

Page 178: ...nstall new conveyor chain guards with new bolts NOTE The conveyor plates B must be replaced when the wear limit of 2 inch 5 mm in the rear area beneath the chain has been reached If components have to...

Page 179: ...F 4 0 1 F_4 0_01_US fm 1 6 F 4 0 Maintenance Auger 1 Maintenance Auger sub unit I 1 2 3 4 5...

Page 180: ...bearing Lubrication 2 q Auger central bearing Lubrication 3 g q Auger drive neck bearing Lubrication 4 g q Auger bevel gear oil level check q Auger bevel gear topping up the oil q Auger bevel gear oi...

Page 181: ...er bearings of the auger must be lubricated when hot so that the eventual bitumen residue is expelled Pump 5 strokes of grease with a grease gun Auger middle bearing 2 The central bearing A is lubrica...

Page 182: ...lug A in the neck of the drive Replace the plug un der it with an extended grease zert 10x1 Use a grease gun to pump about 10 strokes of grease Next unscrew the grease zert and screw back in both plug...

Page 183: ...n til the oil level reaches the lower edge of the inspection hole A Use only ap proved oil Replace the inspection filling plug A To change the oil NOTE Change the oil when the engine is at op erating...

Page 184: ...educed and the blades B have to be replaced Remove the bolts C washers D nuts E and auger blade B Sharp edged parts can cause personal injury Auger blades must be installed with out any play and the c...

Page 185: ...F 5 0 1 F_5 1_01_US fm 1 14 F 5 0 Maintenance Engine 1 Maintenance engine sub unit 1 Fuel Tank Not Shown 2 2 3 6 4 Air Cleaner Not Shown 5 Radiator Not Shown...

Page 186: ...1000 year 2000 2 years as required 1 q Fuel tank Check the filling level q Fuel tank Refill with fuel q Fuel tank Clean the tank 2 q Engine oil system Check oil level q Engine oil system Fill with oil...

Page 187: ...ne cooling system Inspection the radiator fins q Engine cooling system Clean the radiator fins q Engine cooling system Check the level of the coolant q Engine cooling system Fill with coolant q Engine...

Page 188: ...will have to be bled causing work delay To add fuel Unscrew cap A under the tank cov ers r h and l h paver side Fill with fuel through the filler neck until the tank is full Replace the cap A Repeat t...

Page 189: ...ity Avoid inhaling vapors ingestion and common prolonged contact with used engine oil Do not allow used oil to drain into the ground Always used proper proceedures to dis pose of the oil To avoid pers...

Page 190: ...p 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 reache...

Page 191: ...tely Change the pre filter Drain the separated water at the tap C col lect it then close the tap again Remove the water detection indicator connec tion D Loosen the filter cartridge E using an oil fil...

Page 192: ...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 Do not fill the fuel filters with fuel before installing them...

Page 193: ...st vacuator valve Discharge the dust by pressing together the upper part of the valve Cleaning replacing the air filter car tridge NOTE Air intake filter pollution depends on the dust con tent in the...

Page 194: ...once per year Blow out with dry pressure air max 30 psi 2 07 bar from inside blowing out In case of an urgency tap the cartridge to remove dust Check the filter s paper of the filter cartridge by expo...

Page 195: ...l injury from heated coolant spray or steam Remove the filler cap slowly to relieve coolant system pressure Checking filling coolant level The coolant level is checked when the engine is cold Check th...

Page 196: ...r with a 50 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 radiato...

Page 197: ...vibrate This vibration is enough to cause unnecessary wear on the belt s and on the pulleys If the belt s are too tight unnecessary stresses are placed upon the pulley bearings and upon the belts Thes...

Page 198: ...F 5 0 14 F_5 1_01_US fm 14 14...

Page 199: ...F 6 0 1 F_6 0_01_US fm 1 12 F 6 0 Maintenance Hydraulic System 1 Maintenance hydraulic system 1 2 3 5 Hydraulic Hoses Not Shown 4...

Page 200: ...ulic oil tank Check the maintenance indicator q q Hydraulic oil tank Intake return g q q Change the hydraulic filter 3 q High pressure filter Check the maintenance indicator g q q High pressure filter...

Page 201: ...hydraulic system 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 potenti...

Page 202: ...de of the machine With the cylinders fully retracted the oil level should be at the upper mark To add oil Remove cap B Add oil through the fill port until the lev el shows full at the sight level gaug...

Page 203: ...ate contain er using a funnel After draining add a new seal ring and then screw the plug back into place Hot oil or components can burn Oil must be at normal operation temperature when draining Avoid...

Page 204: ...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 follow ing parts li...

Page 205: ...lly into the 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 i...

Page 206: ...ve the filter cartridge Clean the filter housing Insert the new filter cartidge Replace the seal o ring on the filter housing Screw the filter housing on by hand then tight en it using the appropriate...

Page 207: ...to the center of the sight glass To add oil Unscrew the plug B Add oil until the sight glass A shows the cor rect fluid level Return and tighten the plug B Keep the work area clean Hot oil or componen...

Page 208: ...tch 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...

Page 209: ...operation temperature when draining Avoid con tact with hot oil or components Check the condition of the hydraulic hoses carefully Immediately replace any damaged hoses Old hoses may become porous an...

Page 210: ...F 6 0 12 F_6 0_01_US fm 12 12...

Page 211: ...1 F_7 1_01_US fm 1 8 F 7 1 Maintenance Travel Drive Steering 1 Maintenance travel drive steering 4 2 1 3...

Page 212: ...il level of the planetary gear q Check the oil level of the planetary gear drive q Planetary gear drive Change the oil 3 q Air pressure drive wheels check q Air pressure drive wheels adjust 4 q Lubric...

Page 213: ...nuts have to be tighten in the described order with a torque of 375 ft lbs 508 Nm dry thread Front wheels with front wheel drive The 10 wheel mounting nuts have to be tighten in the described order wi...

Page 214: ...bout the 6 o clock position The oil filler plug C should then be on the Left or Right outside fo the planetary middle Clean the area around the check and fill plugs and the drain plug Place an oil col...

Page 215: ...the machine so that the TOP is at the topmost position and the drain plug is at the bottom Place an oil collection container underneath the planetary gearbox Unscrew the drain plug and the filling pl...

Page 216: ..._01_US fm 6 8 Air pressure driving wheels 3 Check adjust the air pressure The required tire pressure is 45 psi pounds per square inch for each tire Check the air pressure at the valve and adjust as re...

Page 217: ...gh a lubrication line Pump the grease gun 5 times into the zert at the end of the lubrication line for the steering linkage Wheel bearing The grease zerts are found on the wheel hub of each wheel Ther...

Page 218: ...Low quality oil or lubricant causes faster wear and the failure of the machine Mixing of synthetic and natural oils is explicitly prohibited Filling volumes Grease Dynapac Paver Grease Gear oil machi...

Page 219: ...1 F_8 1_01_US fm 1 8 F 8 1 Maintenance Electronic System 1 Maintenance Electronic system 1 3...

Page 220: ...al Maintenance point Note 10 50 100 250 500 1000 annually 5000 20000 If necessary 1 q Check the charge level of the batteries replace if necessary q Apply grease to battery terminals 3 q Electric fuse...

Page 221: ...free of corrosion ox ide and protected with grease When removing the batteries always remove the negative terminal first ensuring that the battery termi nals do not short circuit After batteries are r...

Page 222: ...fm 4 8 Electric fuses relays 3 Main fuses A Fuse No Description Rating A F1 Main Battery Fuse 100 F2 Alternator Fuse 100 F3 Key Switch Line Fuse 50 F4 Air Heater Fuse 125 F7 ECM Power Supply Fuse 30 F...

Page 223: ...ter 10 F13 Propel Devices 10 F14 Console Select Switch and Parking Brake 5 F15 Auger Conveyor On Off and Auto Manual Switch 5 F17 Auger Raise Lower 10 F18 Tow Arm Levelling Control 10 F19 Screed Raise...

Page 224: ...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 Conv...

Page 225: ...Air Heater 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 Indica...

Page 226: ...8 F_8 1_01_US fm 8 8...

Page 227: ...ubricating 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 sectio...

Page 228: ...01_US fm 2 4 1 1 Maintenance intervals Item Interval Maintenance point Note 10 50 100 250 500 1000 annually 2000 every 2 years If necessary 1 q Bearing points Maintenance q Maintenance during the brea...

Page 229: ...F 9 0 3 F_9 0_01_US fm 3 4 1 2 Points of maintenance Bearing points 1 One grease zert A is located at each hydraulic cylinder bearing point top and bottom A 2x...

Page 230: ......

Page 231: ...F10 0 1 F_10 0_01_US fm 1 6 F10 0 Checks Decommissioning 1 Tests check up cleaning stopping...

Page 232: ...ls No Interval Points of maintenance Remark 10 50 100 250 500 1000 year 2000 2 years as required 1 q General observation 2 q q Checked by a specialist 3 q Cleaning 4 q Preservation for storage of pave...

Page 233: ...locking points 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...

Page 234: ...ne with water after laying mineral mixes lean concrete etc Re move all residue of the materials laid Do not spray water on the bearings electric or electronic parts Remove the residue of the material...

Page 235: ...metal surfaces i e hydraulic cylinder piston rods against corrosion us ing an appropriate agent If the machine cannot be parked in a garage barn or a shed it must be covered with an appropriate canvas...

Page 236: ...sposal 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 electro...

Page 237: ...ng 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 oi...

Page 238: ...il 1 4 gal 5 3 L Planetary gear track 80W 140 full synthetic oil 0 8 gal 3 0 L each Conveyor gear box 80W 140 full synthetic oil 1 58 qt 1 5 L each Auger center gear box 80W 140 full synthetic oil 2 6...

Page 239: ...le service outlets if you encounter any operational problems or have enquiries about spare parts Our trained specialist staff will ensure that you receive prompt attention and repairs in the event of...

Page 240: ...www atlascopco com...

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Atlas Copco Dynapac F1000W T4i, Operation & Maintenance Manual

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