Dynapac F1000T Page 6 Operation & Maintenance Manual Download

Page: 6 / 238

US_

rack_

10ftIVZ.fm 4-6

02-0

103

2.2

Malfunctions on the paver or screed ........................................................ 24

E01

Set-up and modification ......................................................... 1

Special notes on safety .............................................................................. 1

Auger ......................................................................................................... 2

2.1

Height adjustment ...................................................................................... 2

2.2

Auger crossbeam - hydraulic height adjustment ........................................ 2

2.3

Auger extension ......................................................................................... 3

2.4

Mounting extension parts ........................................................................... 4

2.5

Mounting support tube extensions ............................................................. 5

2.6

Installing tunnel plates ............................................................................... 6

2.7

Installing additional braces ......................................................................... 7

Screed ........................................................................................................ 8

Electrical connections ................................................................................ 8

4.1

Remotes from screed to paver ................................................................... 8

4.2

Right hand conveyor sensor control .......................................................... 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

F1.0

Maintenance ............................................................................ 1

Notes regarding safety ............................................................................... 1

F2.0

Maintenance overview ............................................................ 1

Maintenance overview ............................................................................... 1

F3.0

Maintenance - Conveyor ........................................................ 1

Maintenance - Conveyor ............................................................................ 1

1.1

Maintenance intervals ................................................................................ 2

1.2

Points of maintenance ............................................................................... 3

Chain tension of the conveyor (1) .......................................................... 3

Conveyor tensioning sprocket bearings (2) ........................................... 5

Conveyor bearing (3) ............................................................................. 5

Conveyor drive - (5) drive chains ........................................................... 6

Conveyor drive - (6) planetary drive (left/right) ..................................... 7

Conveyor chain guards / conveyor plates (7) ........................................ 8

F4.0

Maintenance - Auger ............................................................... 1

Maintenance - Auger sub-unit I .................................................................. 1

1.1

Maintenance intervals ................................................................................ 2

1.2

Points of maintenance ............................................................................... 3

Auger - outer bearing (1) ...................................................................... 3

Auger middle bearing (2) ....................................................................... 3

Auger - drive gear neck bearing (3) ....................................................... 4

Auger bevel gear (on the RH and LH sides) (4) .................................... 5

Auger blade (5) ...................................................................................... 6

F5.0

Maintenance - Engine ............................................................. 1

Summary of Contents for F1000T

Page 1: ...08FEB2010 OPERATION MAINTENANCE Keep this manual for future reference Order number for this manual D717 41 00 38 Paver F1000T Type 717...

Page 2: ...VALUE QUALITY THE ORIGINAL Your Authorized Dynapac Dealer...

Page 3: ...4 4 Weights F1000T 9 4 5 Performance data 9 4 6 Engine 10 4 7 Hydraulic system 10 4 8 Material compartment hopper 10 4 9 Electrical system 10 4 10 Operator stations 10 4 11 Conveyors 11 4 12 Auger 11...

Page 4: ...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 Main Menu Diagnostics 7 Main Menu Diagnosti...

Page 5: ...red 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 paver 5 Before starting the paver 5 Normal starting 5 Jump...

Page 6: ...r control 9 4 5 Left hand auger sensor control 9 F1 0 Maintenance 1 1 Notes regarding safety 1 F2 0 Maintenance overview 1 1 Maintenance overview 1 F3 0 Maintenance Conveyor 1 1 Maintenance Conveyor 1...

Page 7: ...lic hoses 5 10 F7 0 Maintenance Track 1 1 Maintenance running gear 1 1 1 Maintenance intervals 2 2 Instructions for undercarriage maintenance 3 2 1 Long term effect of parked machines 4 2 2 Maintenanc...

Page 8: ...ntervals 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 R...

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

Page 10: ...V 2 V_01_US fm Dynapac USA Inc 2100 N First Street Garland Texas 75040 Telephone 972 496 7400 Fax 972 496 7310 www dynapac com...

Page 11: ...alerts prohibitions and instructions refer to the risks to which people machinery and environment are exposed Ignoring these instructions bans and commands may lead to fatal injuries Furthermore the...

Page 12: ...rushing Operation of certain parts or functions and moving the machine can produce a risk of crushing Always make sure that no one is in the areas exposed to risk Caution risk of hand injury Caution h...

Page 13: ...V 5 V_01_US fm Caution materials harmful to health and irritating substances Caution flammable materials Caution gas bottles...

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: ...cle description 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 agg...

Page 22: ...Standard Track drive wheel 8 Standard Levelling cylinder for paving thickness 9 Standard Levelling arm guide 10 Standard Guide roller Side arm tow point 11 Standard Idler 12 Standard Screed side arm 1...

Page 23: ...e 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 pa...

Page 24: ...ot The eletronic synchroisation 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...

Page 25: ...idths Levelling slope control system The slope control system allows the paving thick ness to be regulated at the left hand or the right hand side with a defined difference to the opposite side To det...

Page 26: ...m 6 18 3 Danger zones In the working areas around the machine marked in red there may be a risk of draw ing in or crushing during normal operation caused by rotating and conveying ele ments or by comp...

Page 27: ...1 Dimensions For screed technical data refer to the screed operating instructions Carlson EZ IV 129 119 5 in 95 in 256 in 79 in 129 in 120 in 60 in 101 in 274 in w optional equip 152 cm 327 cm 200 cm...

Page 28: ...ng your machine in an inclined position gradient slope lateral inclina tion which is above the specified limit value please consult the customer service de partment for your machine 4 3 Permissible ap...

Page 29: ...0 lbs 13608 kg 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 26 7 92 f...

Page 30: ...directly flanged to the engine Pressure distribution Hydraulic circuits for Propel system Auger drive system Works system conveyor hydraulic cylinders Generator system Vibration system Front wheel sy...

Page 31: ...pacities for the various lubricants and operating substances see chapter F Conveyor type Dual independent slat conveyor Conveyor control Proportional speed control both side driven inde pendently Auge...

Page 32: ...B 12 B_F1000T_US fm 12 18 5 Location of instruction labels and identification plates 1 2 3 5 6 8 4 6 7 7 9 12 10 13 5 6...

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: ...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 damage could result from high nois...

Page 35: ...B 15 B_F1000T_US fm 15 18 14 Location of technical manuals on the machine Item Decal Description...

Page 36: ...den tification number 8 Item Designation 1 Paver type 2 Year of construction 3 Serial number of the paver series 4 Max permissible operating weight incl all extension parts in lbs kg 5 Max permissible...

Page 37: ...e 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 93 5 dB A 92 6 dB A Sound capacity level LWA 122 34 d...

Page 38: ...rical measuring 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...

Page 39: ...f 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...

Page 40: ...fic 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 assist...

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

Page 42: ...C 1 0 4 C_1 0_01_US fm 4 16 1 7 10 4 11 5 8 2 9 12...

Page 43: ...ift 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 preselect...

Page 44: ...eed 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 to the low bed trailer Use only proper and p...

Page 45: ...s Swing 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 scree...

Page 46: ...ed 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 the paver and screed see als...

Page 47: ...C 1 0 9 C_1 0_01_US fm 9 16 7 4 5 11 9 2 8 10 1 12...

Page 48: ...Lift 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 preselec...

Page 49: ...C 1 0 11 C_1 0_01_US fm 11 16 3 2 Driving mode 3 1 2...

Page 50: ...12 16 Press the emergency stop button when an emergency situation arises Step Operation 1 Turn the selector to position 3 2 Turn the pre selecting regulator to its maxi mum point 3 Use the drive leve...

Page 51: ...able 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 o...

Page 52: ...oose 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 l...

Page 53: ...al rolling or is already properly connected to the towing vehicle Attach the towing device to the tie down points located in the bumper un der the hopper Push down and turn the Pump Pres sure Lock and...

Page 54: ...ust be secured in such a way that unauthorized persons or playing children cannot damage the vehicle Remove the ignition key and the main switch 1 and take it with you do not hide them somewhere on th...

Page 55: ...d 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 im...

Page 56: ...D 1 0 2 D_1 0_01_US fm 2 42 2 Controls 2 1 Operating panel 1 2 A B C D 4 3 4 3 2 1 C D B A Left Hand Operator s Panel Right Hand Operator s Panel...

Page 57: ...h Secures the adjustable operating panel into position Pull the locking knob and swivel the operating panel to the desired position Allow the latch to engage in one of the possible positions again Whe...

Page 58: ...D 1 0 4 D_1 0_01_US fm 4 42 PANEL A 10 14 11 12 15 13 14 11 12 15 13 Right Hand Operator s Panel Left Hand Operator s Panel...

Page 59: ...tor switch 13 Straight ahead travel trimming This potentiometer has the following functions Steering the paver through a large curved radius Turn the potentiometer in the corresponding direc tion unti...

Page 60: ...e both halves of the hopper Toggle switch function Toggle the switch forward away from the operator Close hoppers Toggle the switch back toward the operator Open hoppers Do not open or close the hoppe...

Page 61: ...D 1 0 7 D_1 0_01_US fm 7 42 PANEL B 28 30 29 22 23 20a 21 25 26 27 26 21 22 30 20 20a 20 Left Hand Operator s Panel Right Hand Operator s Panel...

Page 62: ...uger on 3rd position Travel drive propel on increase speed by turning the speed control until it stops The maximum speed is set with the travel drive engine preselector switch and with the travel driv...

Page 63: ...D 1 0 9 D_1 0_01_US fm 9 42 PANEL B 28 30 29 22 23 20a 21 25 26 27 26 21 22 30 20 20a 20 Left Hand Operator s Panel Right Hand Operator s Panel...

Page 64: ...not used 24 not used 25 Working lights ON OFF Switches the working lights on and off Toggle switch function Toggle the switch to setting 0 Working lights OFF Toggle the switch to setting 1 Working lig...

Page 65: ...D 1 0 11 D_1 0_01_US fm 11 42 PANEL B 28 30 29 22 23 20a 21 25 26 27 26 21 22 30 20 20a 20 Left Hand Operator s Panel Right Hand Operator s Panel...

Page 66: ...Toggle the switch to setting 1 Tamper ON NOTE 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 act...

Page 67: ...D 1 0 13 D_1 0_01_US fm 13 42 PANEL C 46 45 47 48 43 44 41 42 40...

Page 68: ...ay from the operator Conveyor OFF Toggle the switch back toward the operator Con veyor is at 100 feed capacity 42 Right conveyor OFF max output Overrides the conveyor function in automatic mode Toggle...

Page 69: ...D 1 0 15 D_1 0_01_US fm 15 42 PANEL C 46 45 47 48 43 44 41 42 40...

Page 70: ...de conveyor auger AUTO activation LED MANUAL acti vation LED Toggles between AUTOMATIC and MANUAL operating modes for the conveyor auger Toggle switch function Toggle the switch forward away from the...

Page 71: ...D 1 0 17 D_1 0_01_US fm 17 42 PANEL C 46 45 47 48 43 44 41 42 40...

Page 72: ...me time to keep the auger crossbeam level Do not raise or lower the auger until all equipement and persons are clear of the machine 48 Raise lower right auger Hydraulically adjusts the height of the r...

Page 73: ...D 1 0 19 D_1 0_01_US fm 19 42 PANEL D 53 54 55 51 50 52 53 52 51 50...

Page 74: ...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 75: ...D 1 0 21 D_1 0_01_US fm 21 42 PANEL D 53 54 55 51 50 52 53 52 51 50...

Page 76: ...back toward the operator 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...

Page 77: ...D 1 0 23 D_1 0_01_US fm 23 42 PANEL D 53 54 55 51 50 52 53 52 51 50...

Page 78: ...nd or lower leveling cylinder Do not raise or lower the leveling cylinder until all equip ment and persons are clear of the machine 55 Right leveling cylinder To manually extend and retract the leveli...

Page 79: ...D 1 0 25 D_1 0_01_US fm 25 42 3 Auxiliary functions 60 61 62...

Page 80: ...flu id 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 dr...

Page 81: ...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 82: ...D 1 0 28 D_1 0_01_US fm 28 42 Left right remote control 70 73 71 75 77 78 86 85 84 83 82 80 70 72 74 76 77 79 87 85 84 83 82 81...

Page 83: ...des the auger function in automatic mode Toggle switch function Toggle the switch left Auger OFF Toggle the switch right Auger 100 feed capacity 73 Left conveyor OFF max output Overrides the conveyor...

Page 84: ...switch The conveying direction of the right half of the auger can be re versed in order to slightly reverse a material supply which may be too high The switch can be activated as often as needed to al...

Page 85: ...D 1 0 31 D_1 0_01_US fm 31 42 70 73 71 75 77 78 86 85 84 83 82 80 70 72 74 76 77 79 87 85 84 83 82 81...

Page 86: ...are clear of the machine 79 Right leveling cylinder Manually extends and retracts the leveling cylinder when the ve hicle is being operated without the automatic leveling system Toggle switch function...

Page 87: ...ulically 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 operat...

Page 88: ...D 1 0 34 D_1 0_01_US fm 34 42 70 73 71 75 77 78 86 85 84 83 82 80 70 72 74 76 77 79 87 85 84 83 82 81...

Page 89: ...ator Raise extension scope Toggle the switch back toward the operator Lower extension scope Before operating the toggle switch ensure that eqipment and persons are clear of the machine 84 Berm lock un...

Page 90: ...ward away from the operator Screed heater system ON Toggle the switch back toward the operator Screed heater system OFF 87 Crowning Adjust ment The screed is equipped with adjustable crowning adjustin...

Page 91: ...D 1 0 37 D_1 0_01_US fm 37 42 100 102 104 106 101 103 105 107...

Page 92: ...forward 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 perso...

Page 93: ...ed Hydraulically retracts and extends the right extendable part of the screed Push button function Toggle switch left Retract screed Toggle switch right Extend screed Before operating the toggle switc...

Page 94: ...D 1 0 40 D_1 0_01_US fm 40 42 100 102 104 106 101 103 105 107...

Page 95: ...D 1 0 41 D_1 0_01_US fm 41 42 Item Designation Brief description 106 Handset connec tion cable Connects to the left remote control 107 Handset connec tion cable Connects to the right remote control...

Page 96: ...D 1 0 42 D_1 0_01_US fm 42 42...

Page 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 102: ...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 103: ...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 104: ...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 105: ...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 106: ...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 107: ...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 108: ...gle view display To select signals for display press the far right soft key Quick Data softkey Scroll through signal list us ing the up and down arrow soft keys and select de se lect signals for Quic...

Page 109: ...D 2 0 13 D_2 0_01_US fm 13 24 Start Display Appears at system start 1 2 3 4...

Page 110: ...in rpm with bar chart Diesel tank filling 3 in with bar chart Engine Coolant Tempera ture 4 in F Display 02 Display menu Actual Engine Torque 1 in Engine RPM 2 in rpm with bar chart Actual Engine Tor...

Page 111: ...he Active Fault Screen Scroll thru the faults by using buttons 2 or 3 To leave the Active Fault Screen press button 1 Fault Sources and Codes Nr Source 1 Sensor Power 2 Battery 3 Left Joystick 4 Right...

Page 112: ...D 2 0 16 D_2 0_01_US fm 16 24 Nr Cause of Issue 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...

Page 113: ...selector when machine is stopped Change Propel selector switch while joystick is not neutral 4 Change propel selector when joystick is in neutral Joystick not in neutral when machine is powered up 5 R...

Page 114: ...D 2 0 18 D_2 0_01_US fm 18 24 1 2 Engine Error messages...

Page 115: ...D 2 0 19 D_2 0_01_US fm 19 24...

Page 116: ...D 2 0 20 D_2 0_01_US fm 20 24...

Page 117: ...D 2 0 21 D_2 0_01_US fm 21 24...

Page 118: ...D 2 0 22 D_2 0_01_US fm 22 24...

Page 119: ...D 2 0 23 D_2 0_01_US fm 23 24 1 3 FMI codes...

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

Page 121: ...nsole 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 Operating panel The operating p...

Page 122: ...nto place Seat back rest adjustment 2 The back rest can be adjusted to lean for ward or lean back To adjust the back rest turn the knob on the lower front part of the seat Turn the knob clockwise to l...

Page 123: ...e circuit between the battery and the main fuse is located under the center maintenance door See chapter F for fuse locations and fuse order To switch the ignition off turn the key 1 to the left and p...

Page 124: ...yor Mechanical screed transport safe guard to the left and the right be neath the driver s seat Used to protect the lifted screed from in advertent lowering The screed transport safeguard must be inse...

Page 125: ...on the Scale 2 In normal paving situations the same paving thickness should be set on both sides of the vehicle Before transporting the vehicle ensure the Paving Thickness Indicator and the Scale swi...

Page 126: ...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 sto...

Page 127: ...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 th...

Page 128: ...imit sensors control the material flow at the respective auger half The ultrasonic sensor is mounted to the side plate Loose clamping lever for ad justment and modify angle height of the sensor The ca...

Page 129: ...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 130: ...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 131: ...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 132: ...D 4 0 4 D_4 0_01_US fm 4 26 40 20 21 10 12 40 20 21 12...

Page 133: ...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 134: ...D 4 0 6 D_4 0_01_US fm 6 26 40 20 21 10 12 40 20 21 12...

Page 135: ...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 136: ...D 4 0 8 D_4 0_01_US fm 8 26 40 20 21 10 12 40 20 21 12...

Page 137: ...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 138: ...D 4 0 10 D_4 0_01_US fm 10 26 40 47 48 52 54 55 20 21 10 12 40 47 48 52 20 21 12...

Page 139: ...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 140: ...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 141: ...D 4 0 13 D_4 0_01_US fm 13 26 45 46 20 21 15 45 46 20 21 15...

Page 142: ...position Set the selector 21 for traction drive engine to position 2 and push the drive lever 20 forward away from operator Conveyor and auger will begin to work The limit sensors for the conveyors an...

Page 143: ...D 4 0 15 D_4 0_01_US fm 15 26 45 46 53 27 28 20 21 24 12 45 46 20 21 12 53...

Page 144: ...ng 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 whee...

Page 145: ...re 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 Malfuncti...

Page 146: ...D 4 0 18 D_4 0_01_US fm 18 26 45 27 28 20 25 21 24 10 12 45 20 21 12...

Page 147: ...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 148: ...D 4 0 20 D_4 0_01_US fm 20 26 45 47 48 54 52 55 50 51 27 28 20 25 21 24 10 12 45 48 47 52 54 50 51 20 21 12...

Page 149: ...oth screed lifting cylinders While operating the tampers at a low speed let any material residue drop out Switch the ignition 10 off Switch screed heater system off Remove the levelling units and stow...

Page 150: ...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 151: ...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 152: ...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 153: ...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 154: ...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 155: ...chine 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 t...

Page 156: ...ems 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 b...

Page 157: ...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 the...

Page 158: ...or rounded stone to prevent segregation If alsready mount ed 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 159: ...ccurs 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 ones...

Page 160: ...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 scopic...

Page 161: ...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 prov...

Page 162: ...aver socket 15 The paver and the screed communicate through this con nection 4 2 Right hand conveyor sensor control The Conveyor Sensor plugs into the re mote control unit on the right hand side at so...

Page 163: ...t socket 16a 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 plugs into the remote control unit on the left hand...

Page 164: ...E 01 10 E_01_US fm 10 10 4 6 Auger Chart...

Page 165: ...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 166: ...F 1 0 2 F_1 0_01_US fm 2 2...

Page 167: ...F 2 0 1 F_2 0_01_US fm 1 2 F 2 0 Maintenance overview 1 Maintenance overview 3 0 5 0 8 0 6 0 9 0 10 0 7 0 4 0...

Page 168: ...100 250 500 1000 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 Track F7 0 q q q q q Electroni...

Page 169: ...F3 0 1 F_3 0_01_US fm 1 8 F3 0 Maintenance Conveyor 1 Maintenance Conveyor 1 2 3 4 5 6 7 1...

Page 170: ...ing sprocket Lubricate 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 dri...

Page 171: ...000 hours of operation and before ad justing 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 stoppag...

Page 172: ...ead to the destruction 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 replaced in sets Conveyor ch...

Page 173: ...e outer lubricating grease zerts Pump 5 strokes of grease with a grease gun Conveyor bearing 3 The conveyor bearings are lubricated with grease zerts B located behind the crossbeam r h side Pump 5 str...

Page 174: ...ension 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...

Page 175: ...f 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 op erating...

Page 176: ...stall new conveyor chain guards with new bolts NOTE The conveyor plates B must be re placed when the wear limit of 2 inch 5 mm in the rear area beneath the chain has been reached If components have to...

Page 177: ...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 178: ...er bearing Lubrication 2 q Auger central bearing Lubrication 3 q Auger drive neck bearing Lubrication 4 q Auger bevel gear oil level check q Auger bevel gear topping up the oil q Auger bevel gear oil...

Page 179: ...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 180: ...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 181: ...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 182: ...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 183: ...F 5 0 1 F_5 0_01_US fm 1 14 F 5 0 Maintenance Engine 1 Maintenance engine sub unit 1 Fuel Tank Not Shown 2 2 2 3 6 4 Air Cleaner Not Shown 5 Radiator Not Shown...

Page 184: ...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 185: ...ine 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 Engin...

Page 186: ...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 187: ...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 188: ...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 t...

Page 189: ...iately 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 fil...

Page 190: ...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 191: ...y pressing together the upper part of the valve B Clean the vacuator valve periodically Cleaning replacing the air filter car tridge NOTE Air intake filter pollution depends on the dust content in the...

Page 192: ...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 exposing to light and inspect the seals Replace them as required Rep...

Page 193: ...ine Wait until the temperature is below 120 F 50 C before removing the pressure cap Failure to do so can result in per sonal injury from heated coolant spray or steam Remove the filler cap slowly to r...

Page 194: ...d pets Dispose of in accordance with federal state and local environmental regulations Close the drain valve Fill the radiator with a 50 50 mix of water and ethylene glycol or propylene glycol antifre...

Page 195: ...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 stress es are placed upon the pulley bearings and upon the belts The...

Page 196: ...F 5 0 14 F_5 0_01_US fm 14 14...

Page 197: ...F 6 0 1 F_6 0_01_US fm 1 10 F 6 0 Maintenance Hydraulic system 1 Maintenance hydraulic system 1 2 3 5 Hydraulic Hoses Not Shown 4...

Page 198: ...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 199: ...e pump drive gear box which is mounted directly to the engine The hydraulic system includes various motors cylinders valves filters and hose piping A hydraulic oil cooler assures optimum oil tempera t...

Page 200: ...ion Recommended hydraulic oils 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 con tainer using a funnel After drainin...

Page 201: ...t 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...

Page 202: ...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 con tainer Start the engine and run...

Page 203: ...lean 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 tighten it using the appropriate tool Test the filter for...

Page 204: ...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 Keep the work area clean Hot oil or componen...

Page 205: ...se in an appro priate 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 dist...

Page 206: ...operation temperature when draining Avoid contact with hot oil or components Check the condition of the hydraulic hoses carefully Immediately replace any damaged hoses Old hoses may become porous and...

Page 207: ...F 7 0 1 F_7 0_01_US fm 1 10 F 7 0 Maintenance Track 1 Maintenance running gear Drive Wheel 1 Idler 2 Guide Rollers Rubber Track Bogie Wheels 3 4...

Page 208: ...rollers drive wheels Ensure proper torque for bolts 2 q Guide rollers check straight run ning q Guide rollers straight running setting g q Guide rollers ensure the adjust ing bolts are tight q Guide...

Page 209: ...simply put 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 opti...

Page 210: ...ible If the 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...

Page 211: ...should be checked and tight ened if necessary The mounting bolts should be tightened to the following torque values Guide rollers A 12 rollers 105 ft Ibs 142 4 Nm Idlers B 2 idlers 314 ft Ibs 425 7 Nm...

Page 212: ...A Retighten the outer adjusting bolt B Never turn the adjusting bolts more than a half turn If the guide rollers run excessively outwards you should adjust the guide rollers in the opposite direction...

Page 213: ...position The oil filler plug A should then be on the Left or Right outside fo the plane tary middle Clean the area around the check and fill plugs and the drain plug Place an oil collection container...

Page 214: ...igher fule 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 bear ing a...

Page 215: ...nt causes faster wear and the failure of the machine Mixing of synthetic and natural oils is explicitly prohibited 3 2 Filling volumes BP Esso Total Fina Total Mobil Renault Shell Wisura Grease BPuniv...

Page 216: ...F 7 0 10 F_7 0_01_US fm 10 10...

Page 217: ...F 8 0 1 F_8 0_01_US fm 1 8 F 8 0 Maintenance Electronic system 1 Maintenance Electronic system 1 3...

Page 218: ...nterval 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...

Page 219: ...The battery terminal clips must be free of corrosion oxide and protected with grease When removing the batteries always remove the negative terminal first ensuring that the battery terminals do not s...

Page 220: ...US 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 3...

Page 221: ...vices 10 F14 Console Select switch parking brake 5 F15 Auger Conveyor status LED s on Console 5 F16 Auger Conveyor Controller Sensor 15 F17 Auger Hopper Raise Lower 10 F18 Levelling Controls 10 F19 Sc...

Page 222: ...F 8 0 6 F_8 0_01_US fm 6 8 Fuse No Description Rating A F31 Wash Down Truck Hitch 3 F32 Screed Power Supply 15 F33 Screed Power Supply 15 F34 FWA Switch Steering Position Sensors 3...

Page 223: ...Air Heater K5 Auger Conveyor ON OFF K6 Auger Conveyor Auto Manual K7 Auger Conveyor Auto Mode K8 Left Conveyor OFF K9 Right Conveyor OFF K10 Starter Lock Out K11 Screed Float Lock K12 Console Select...

Page 224: ...F 8 0 8 F_8 0_01_US fm 8 8...

Page 225: ...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 226: ...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 227: ...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 228: ......

Page 229: ...F 10 0 1 F_10 0_01_US fm 1 6 F 10 0 Checks decommissioning 1 Tests check up cleaning stopping...

Page 230: ...als 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 pav...

Page 231: ...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 232: ...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 233: ...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 234: ......

Page 235: ...cities Incorrect oil or lubricant levels increase the wear and cause the paver to fail Never mix synthetic oils with mineral oils BP Exxon Total Fina Total Mobil Shell Shell Grease Engine oil See Oper...

Page 236: ...gear 80W 140 full synthetic oil 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 gear box 80W 140...

Page 237: ...repair OPERATING ADVICE Anytime when our dealers cannot help you please feel free to contact us di rectly Our team of Technical Advisors is at your disposal TRAINING EDUCATION We offer our Customers...

Page 238: ...Don t hesitate to contact your local dealer for service spare parts documentation accessories and information about the complete Dynapac paving and planing range...

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Dynapac F1000T, Operation & Maintenance Manual

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