Dynapac Hatz F80W Workshop Manual Download Page 234

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230

F80W

16 Appendices

Machine wiring diagram

Legend:

A1 Diesel engine

A2 BODAS RC control unit

A3 Display unit

A4 Travel control lever

A5 Diagnostic socket

A6 Screed heating unit 1 (left)

A7 Screed heating unit 2 (middle)

A8 Screed heating unit 3 (right)

A9 Engine control unit

F1 - F8 Fuses

F9 Main fuse

F10 Engine control unit fuse

G1 Battery

G2 Alternator

H1 Beacon

H2 Auger lighting

I1 Burner ignition (left)

I2 Burner ignition (middle)

I3 Burner ignition (right)

K2 - K6 Relays

K10 Relay

M1 Hydraulic oil cooling fan

M2 Starter

M3 Fuel pump

P1 Horn

P2 Back signal horn

R1 Preheating

R2 Pump turning potentiometer

R3 – R6 Resistor

S1 Disconnecter

S2 Emergency brake button

S3 Ignition box

S5 Hydraulic oil temperature switch

S6 Brake pressure switch

S7 Travel switch

S8 Foot switch

S9 Horn button

S10 Left smoothing screed extension switch

S11 Right smoothing screed extension switch

S12 Smoothing screed lifting switch

S13 Vibration switch

S14 Smoothing screed heating switch

S15 Conveyor direction switch

S16 Automatic mode switch

S17 Operating mode switch

S18 Screed temperature switch

S19 Engine operating speed switch

S20 Engine oil pressure sensor

S21 Engine temperature switch

S22 Engine speed sensor

S23 Engine oil temperature sensor

S24 Fuel injection valve

Y1 Conveyor/auger solenoid valve, right

Y2 Conveyor/auger solenoid valve, reversing

Y3 Left smoothing screed extension solenoid valve

Y4 Left smoothing screed retraction solenoid valve

Y5 Right smoothing screed retraction solenoid valve

Y6 Right smoothing screed extension solenoid valve

Y7 Brake solenoid valve

Y8 Floating smoothing screed solenoid valve

Y9 Smoothing screed release solenoid valve

Y10 Smoothing screed lifting solenoid valve

Y11 Vibration solenoid valve

Y12 Forward travel valve solenoid valve

Y13 Reverse travel valve solenoid valve

Y14 Solenoid of the gas shut-off valve

Y15 Solenoid of the gas shut-off valve

Summary of Contents for Hatz F80W

Page 1: ...WORKSHOP MANUAL Asphalt paver wheeled F80W Hatz 4812077915...

Page 2: ......

Page 3: ...F80W Asphalt paver wheeled Hatz Workshop manual Edition 10 2021 EN From Serial No 3016546...

Page 4: ......

Page 5: ...figures are reserved All dimensions and weights are approximate and therefore not binding DYNAPAC reserves the right to perform modifications at any time with no obligation to inform the machine user...

Page 6: ...4 5 2 Fuel 35 5 3 Hydraulic oil 35 5 4 Anti adherent solution 35 5 5 Liquid gas 36 5 6 Lubricating grease 36 5 7 Fluids 37 6 LUBRICATION AND MAINTENANCE CHART 39 7 ENGINE 43 7 1 Description of engine...

Page 7: ...verse travel 84 9 2 5 Measuring the resistance of the electromagnet coil 86 9 3 Removal of the travel pump 86 9 4 Dismounting the hydraulic motor and travel gearbox 88 9 5 Mounting the hydraulic motor...

Page 8: ...valve electromagnets 146 13 8 3 Measuring power supply of the coils of gas supply valve electromagnets 147 13 9 Ignition units 148 13 9 1 Measuring resistance on the ignition unit 148 13 9 2 Voltage m...

Page 9: ...witch measurement 198 15 2 7 Travel controller measurement 199 15 2 8 Paving speed selector measurement 201 15 3 Calibration 204 15 3 1 Connecting the machine to PC 204 15 3 2 Calibration of the trave...

Page 10: ...6 F80W...

Page 11: ...7 F80W WORKSHOP MANUAL 1 Introduction...

Page 12: ...n the basis of operational experience and the latest findings Due to develop ment the manufacturer reserves the right to change the images descriptions procedures and designs presented in this manual...

Page 13: ...or other personal hazards The notice warns of possible damage to the machine or its parts The notice warns of the necessity of environmental protection CAUTION As used in this operating manual the ter...

Page 14: ...10 F80W...

Page 15: ...11 F80W WORKSHOP MANUAL 2 Safety measures and instructions...

Page 16: ...ame against relative rotation with a lock pin and rod Before starting work remove the key from the ignition disconnect the batteries and allow hot parts to cool Attach a machine out of order sign to t...

Page 17: ...pipes Only use new seals Fill new aggregates with hydraulic oil before installation After a hydraulic aggregate replacement flush the hydraulic circuit and clean the hydraulic tank Replace the oil fi...

Page 18: ...nt of milk magnesium oxide dissolved in water or at least water and immediately seek medical treatment Never fill the cells with distilled water unless it is followed by work with the machine or recha...

Page 19: ...hese materials are not allowed to be stored in unla belled bottles or in any other containers considering the likelihood of confusion Possible confusion with foodstuffs or beverages is very dangerous...

Page 20: ...e flammable liquid equal to the capacity of the big gest transport container It must be equipped with portable fire extinguishers For handling the oil and diesel fuel use such vessels as metal barrels...

Page 21: ...17 F80W WORKSHOP MANUAL 3 Machine description...

Page 22: ...18 F80W D452051 26 24 25 35 23 1 5 8 9 27 10 11 12 17 18 19 20 29 28 32 31 33 22 7 34 3 4 13 21 6 14 15 16 3 2 2 30 1 36 3 Machine description...

Page 23: ...int 16 Paving direction indicator 17 Battery disconnecter 18 Conveyor hydraulic motor 19 Battery 20 Screed linear hydraulic motor 21 Material outlet 22 Hydraulic pumps 23 Beacon 24 Gas bottle 25 Fuse...

Page 24: ...20 F80W 451033B 41 41 42 41 37 37 47 47 45 45 46 43 44 38 39 40 40 46 39 51 52 D451032C 48 49 50 3 Machine description...

Page 25: ...ibrators 41 Gas components 42 Main screed 43 Left screed extension 44 Right screed extension 45 Screed tow arm 46 Mechanical extension 47 Paving thickness controller 48 Foot switch 49 Hopper cover 50...

Page 26: ...22 F80W...

Page 27: ...23 F80W WORKSHOP MANUAL 4 Specification manual...

Page 28: ...0W wheeled asphalt paver has been designed and manu factured for the use for Paving asphalt mixtures at hot condition Paving loose mixtures at cold condition The machines are designed for operation in...

Page 29: ...25 F80W D451023 D451024 D451025A WORKSHOP MANUAL Nameplate Serial number of the machine Serial number of the engine Nameplate of the screed Serial number of the screed...

Page 30: ...26 F80W W1 W2 W W3 W4 B L L1 H H1 D451170A A L2 4 Specification manual 4 2 Dimensional drawing of the machine...

Page 31: ...27 F80W WORKSHOP MANUAL A B H H1 L L1 mm 1280 2070 2680 1598 2865 2526 in 50 4 81 5 105 5 62 9 112 8 99 4 L2 W W1 W2 W3 W4 mm 2550 765 640 800 1150 1699 in 100 4 30 1 25 2 31 5 45 3 66 9...

Page 32: ...static stability with an empty hopper Lateral static stability with a full hopper Type of drive Hydrostatic Number of driving axles 1 Steering Type of steering Hydraulic Steering control Hydraulic se...

Page 33: ...ximum paving width without reduction plates standard equipment of the machine mm in 1300 51 2 Minimum paving width with reduction plates mm in 250 9 8 Maximum paving width with reduction plates mm in...

Page 34: ...full hopper screed in the lower po sition Machine descent with an empty hopper screed in the lower position Machine descent with a full hopper screed in the lower posi tion 4 4 Machine gradeability a...

Page 35: ...31 F80W D451175 12 21 WORKSHOP MANUAL Lateral static stability with an empty and full hopper...

Page 36: ...32 F80W...

Page 37: ...33 F80W WORKSHOP MANUAL 5 Specification of operating fluids...

Page 38: ...on To determine the SAE Society of Automotive Engineers viscos ity class the ambient temperature and type of operation where the machine is used are decisive Use of permissible oils according to API C...

Page 39: ...by micro organ isms present in water and soil Always consult with the oil manufacturer or dealer any switching from mineral oil to synthetic or mixing oils of various brands 5 4 Anti adherent solution...

Page 40: ...ion limits in air use a suitable breathing mask Recommended organic fume and vapour filter type A AX No smoking at work Provide adequate area ventilation Always require a material safety data sheet to...

Page 41: ...2412 Fuel tank Fuel according to Chapter 5 2 5 l 1 3 gal US Hydraulic system Hydraulic oil according to Chapter 5 3 20 l 5 3 gal US 2158 Liquid gas Liquid gas according to Chapter 5 5 Maximum weight...

Page 42: ...38 F80W...

Page 43: ...39 F80W WORKSHOP MANUAL 6 Lubrication and maintenance chart...

Page 44: ...fuel and hydraulic system Every 10 hours at the end of work daily 3 6 11 Fuel level check 3 6 12 Cleaning the conveyor 3 6 13 Cleaning the augers Every 50 hours 3 6 14 Clearing the water separator 3...

Page 45: ...ours of operation 3 6 29 Hydraulic oil and hydraulic oil filter replacement Every 1000 hours 3 6 28 Engine oil filter cleaning 3 6 29 Hydraulic oil and hydraulic oil filter replacement 3 6 30 Gas line...

Page 46: ...6 Lubrication and maintenance chart LUBRICATION AND SERVICE PLAN INSPECTION LUBRICATION REPLACEMENT Engine oil Hydraulic oil Lubricating grease Anti adherent solution Specification according to the co...

Page 47: ...43 F80W WORKSHOP MANUAL 7 Engine...

Page 48: ...engine basic elements 1 Glow plug 2 Temperature sensor 3 Lubricating oil pressure switch 4 One way valve 5 Oil pressure switch 6 Electromagnetic fuel filter 7 Air filter 8 Oil dipstick 9 Oil filter 1...

Page 49: ...45 F80W D452045 16 17 D452046 WORKSHOP MANUAL 16 Fuel tank 17 ECU unit...

Page 50: ...etween the minimum and maximum marking with an oil collector 2 2 l 0 58 gal US Engine oil consumption Max 1 of fuel consumption referred to the full load Oil pressure at 100 C Approximately 2 5 bar at...

Page 51: ...er 7 3 1 Measuring glow plug resistance Remove wire no 6 The measured resistance is approximately 0 7 Note In case of the measured value open circuit replace the glow plug 7 3 2 Measuring glow plug po...

Page 52: ...ure of 220 C and the resist ance is approximately 1 8 Before measuring voltage make sure that the key in ignition is in the I position The voltage between wire no 5 and the engine frame is approxi mat...

Page 53: ...ting oil pressure switch screw If the lubricating oil pressure is insufficient measure the closed circuit the resistance is close to zero After starting the engine measure the opened circuit Before me...

Page 54: ...9 D451420 D451418 7 Engine 7 3 5 Measuring engine speed Remove the cover Measure the engine speed using a revolution counter Measure idling of approximately 1200 RPM Measure maximum speed of approxima...

Page 55: ...the charging controller Dismount the charging controller from the machine with the switched off battery disconnecter and with the closed gas bot tle valve Cut off the binding straps Disconnect the wi...

Page 56: ...nt the charging controller to the machine with the switched off battery disconnecter and with the closed gas bottle valve Fasten the controller Connect the wire and connectors of the charging controll...

Page 57: ...6 Dismounting the engine Dismount the engine from the machine with the switched off battery disconnecter and with the closed gas bottle valve Disconnect the battery Disconnect the connectors Dismount...

Page 58: ...54 F80W D452007 D452008 D452009 7 Engine Remove the holder Remove the exhaust clip and holder...

Page 59: ...55 F80W D452010 D451435 D451436 D451437 WORKSHOP MANUAL Remove the lower hose clip Remove pump bolts Move the pump aside and remove the coupling...

Page 60: ...56 F80W D451440 D452011 D452012 7 Engine Remove the screws of the engine holder 4x Remove the air filter cover...

Page 61: ...57 F80W D451651 D451442 D451443 WORKSHOP MANUAL Remove the top engine cover Hang the engine in the lifting lug on the crane...

Page 62: ...unting the engine Mount the engine to the machine with the switched off battery disconnecter and with the closed gas bottle valve Start and place the engine on the rubber metals of the engine Mount th...

Page 63: ...59 F80W D451444 D451435 D451434 D452010 WORKSHOP MANUAL Fit the coupling onto the pump and insert the pump to the en gine Mount the screws of the pump Remove the lifting lug Mount the lower hose clip...

Page 64: ...60 F80W D451428 D452008 D452006 D452009 7 Engine Mount the engine earthing wire Mount the wire to the starter Mount the exhaust clip and holder...

Page 65: ...61 F80W D451651 D451440 D452007 D452005 WORKSHOP MANUAL Mount the holder Connect the connectors Mount the top engine cover Mount the air filter cover...

Page 66: ...62 F80W D451426 7 Engine Connect the battery...

Page 67: ...63 F80W WORKSHOP MANUAL 8 Steering...

Page 68: ...64 F80W D451448 1 2 DD451045 3 D451450 4 8 Steering 8 1 Description of basic elements 1 Service pump 2 Measuring point for pressure measurement 3 Power steering 4 Steering hydraulic motor...

Page 69: ...re using a pressure gauge with a suitable range Perform the measurement with the heated up hydraulic oil Start the engine and set the engine speed adjusting control ler to the maximum speed Measure th...

Page 70: ...ump Perform the replacement of the gear pump with the machine with the switched off battery disconnecter and with the closed gas bottle valve Remove the suction and discharge pump hose Avoid the oil s...

Page 71: ...67 F80W D451453 D451454 D451452 WORKSHOP MANUAL Mount the screws and fasten the pump Mount the suction and discharge hose...

Page 72: ...steering wheel to the maximum right position Remove the cable on the steering hydraulic motor Note Mark the cable e g by an alcohol marker to facilitate back as sembly Remove the screw of the steering...

Page 73: ...69 F80W D451459 WORKSHOP MANUAL Replace the steering hydraulic motor...

Page 74: ...raulic motor and mount the screw Mount the screws of hoses of the steering hydraulic motor Mount the screw of the steering hydraulic motor and glue it with the LOXEAL 83 54 adhesive Mount the cable on...

Page 75: ...the steering unit Dismount the steering unit from the machine with the switched off battery disconnecter and with the closed gas bottle valve Remove the cover Remove the screw Take out the steering wh...

Page 76: ...at position L Hose 0033 at position R 8 8 Removal of the hydraulic tank Drain the heated oil from the hydraulic tank Perform the hydraulic oil draining when the machine is parked on a flat and solid s...

Page 77: ...73 F80W D451467 D451468 D451469 D451470 WORKSHOP MANUAL Remove the hydraulic hoses Avoid the oil soaking into the ground Remove the screws 3x...

Page 78: ...D451467 D451468 8 Steering 8 9 Mounting the hydraulic tank Mount the hydraulic tank to the machine with the switched off battery disconnecter and with the closed gas bottle valve Mount the screws Mou...

Page 79: ...gal US Check the oil level on the oil gauge 2 The hydraulic oil level must be between the MIN and MAX marks 8 10 Adjustment of the front wheel turning angle indicator Adjust the indicator by tightenin...

Page 80: ...76 F80W...

Page 81: ...77 F80W WORKSHOP MANUAL 9 Travel...

Page 82: ...1 Service pump 2 Measuring point for pressure measurement 3 Measuring point for pressure measurement for forward travel 4 Measuring point for pressure measurement for reverse travel 5 Coil of the val...

Page 83: ...79 F80W DD451049 7 DD451050 7 DD451051 8 9 DD451052 WORKSHOP MANUAL 7 Setting the maximum pump volume 8 Setting the neutral pump position 9 Coil of the brake valve electromagnet Y7...

Page 84: ...80 F80W 10 D451053 D451054 11 DD451055 12 DD451056 13 9 Travel 10 Brake pressure switch 11 Pump plate tilt sensor 12 Travel hydraulic motor 13 Travel gearbox...

Page 85: ...r Measuring brake switch pressure Disconnect the hose fittings Insert the jumper with the measuring point to the circuit and connect the pressure gauge with a suitable range to it Start the engine set...

Page 86: ...F80W D451494 D451498 9 Travel 9 2 2 Measuring the brake valve electromagnet Y7 Disconnect the connector from valve Y7 Measure the resistance between outputs of the electromagnet coil of approximately...

Page 87: ...ing the refilling pressure Measure the pressure using a pressure gauge with a suitable range Connect the pressure gauge Start the engine and set the engine speed adjusting controller to the maximum sp...

Page 88: ...51504 D451505 9 Travel 9 2 4 Measuring the maximum pressure for forward and reverse travel Measure the pressure using a pressure gauge with a suitable range Disable the brake release function Secure t...

Page 89: ...85 F80W D451508 D451506 D451507 WORKSHOP MANUAL Measure the maximum pressure to approximately 150 Bar Note In case a different value is measured contact your dealer or DY NAPAC Technical Support...

Page 90: ...nce of approximately 5 3 between out puts of the coil of electromagnets Y12 and Y13 Note There must be an opened circuit between individual inputs and the body of the coil 9 3 Removal of the travel pu...

Page 91: ...87 F80W D451513 D451514 D451515 D451516 WORKSHOP MANUAL Remove all hoses from the pump Remove pump bolts...

Page 92: ...otor and travel gearbox from the ma chine with the switched off battery disconnecter and with the closed gas bottle valve When dismounting the hydraulic motor and travel gearbox pro ceed in the same w...

Page 93: ...89 F80W D451521 D451A522 DD451023 WORKSHOP MANUAL Remove the screws Remove the screws 8x...

Page 94: ...ne with the switched off battery disconnecter and with the closed gas bottle valve When mounting the hydraulic motor and travel gearbox pro ceed in the same way on both sides of the machine Mount the...

Page 95: ...91 F80W D451517 D451518 D451519 WORKSHOP MANUAL Mount the rear wheels Mount the screws...

Page 96: ...92 F80W...

Page 97: ...93 F80W WORKSHOP MANUAL 10 Gear pump...

Page 98: ...94 F80W 1 D451574 D451575 2 D451576 3 D451577 4 10 Gear pump 10 1 Description of basic elements 1 Gear pump 2 Hydraulic block 3 Linear hydraulic motors 4 Vibrators...

Page 99: ...95 F80W D451578 5 DD451057 6 WORKSHOP MANUAL 5 Hydraulic motor for driving the augers and the belt conveyor 6 Steering linear hydraulic motor...

Page 100: ...ing the pressure of the belt conveyor and auger Start the engine Block the travel of the conveyor Start the function of the conveyor by selector switch 18 Let the belt conveyor function running for th...

Page 101: ...t the engine and lift the screed to the maximum position by selector switch 7 Set the engine speed setting switch 10 to the maximum speed up position Let the engine idle for at least for 5 minutes Mea...

Page 102: ...ne and tet the engine speed setting switch 10 to the maximum speed up position Measure the pressure with the closed screed extension Keep the paving width switch right 3 on the left during the meas ur...

Page 103: ...maxi mum position Set the travel controller 8 to the neutral position Using the engine speed setting switch 10 set the maximum engine speed Set the screed to the maximum paving width using the paving...

Page 104: ...screed width with the controls 2 and 3 on the control panel Fix the acceleration sensor of the vibrometer on the screed Measure the pressure of vibrators of approximately 50 Bar Note In case a differ...

Page 105: ...3 Dismounting the gear pump Dismount the gear pump from the machine with the switched off battery disconnecter and with the closed gas bottle valve Remove the suction and discharge gear pump hose Avoi...

Page 106: ...with the controls 2 and 3 on the control panel Turn off the engine disconnect the battery disconnecter and close the gas bottle valve Dismount the vibration units when the machine is parked on a flat...

Page 107: ...103 F80W D451955 D451956 WORKSHOP MANUAL Remove the screws Note During reverse assembly glue the screws with the LOXEAL 83 54 adhesive...

Page 108: ...on pressure safety valve 5E Conveyor electromagnet for forward direction 6E Conveyor electromagnet for reverse direction 7E Vibration electromagnet 8E Screed lifting electromagnet 9E Screed extension...

Page 109: ...ydraulika li ty B4 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 G3 8 G1 2 G1 2 G3 8 G1 4 A4 B3 A3 B2 M4 B1 A1 B A BR M2 D451059 1E 2E 3E 4E 5E 6E 7E 8E 11E 12E 13E 9...

Page 110: ...106 F80W...

Page 111: ...107 F80W WORKSHOP MANUAL 11 Cooling...

Page 112: ...sensor 4 Output 5 Input 11 2 Cooling diagnostics 11 2 1 Fan test Dismount the temperature sensor connector and turn the key in the ignition box to the I position The fan will start 11 2 2 Temperature...

Page 113: ...nd solid surface the battery is switched off and the gas bottle is closed Open the right material hopper side cover 1 Place a vessel with a volume of at least 21 l 5 5 gal US under the hydraulic oil d...

Page 114: ...110 F80W D451479 D451480 D451481 D451482 11 Cooling Remove the hoses of the input and output Loosen the screw and move the horn to the side Remove the screws...

Page 115: ...83 D451484 D451483 D451484 WORKSHOP MANUAL Remove the screws 11 4 Mounting the cooler Mount the cooler to the machine with the switched off battery disconnecter and with the closed gas bottle valve Mo...

Page 116: ...112 F80W D451481 D451482 D451485 D451479 11 Cooling Mount the screws Mount horn and tighten the screw Mount the hoses of the input and output...

Page 117: ...nect the connectors X41 X19 and X20 Fill in the hydraulic tank Fill in new oil to the hydraulic tank through the hole 1 The prescribed oil volume is 20 l 5 3 gal US Check the oil level on the oil gaug...

Page 118: ...114 F80W...

Page 119: ...115 F80W WORKSHOP MANUAL 12 Screed...

Page 120: ...e engine speed setting switch 10 set the maxi mum engine speed Switch over the transport operating mode switch 15 to the upper position Press the foot switch 48 To lower the screed switch over the scr...

Page 121: ...117 F80W D451584 D451589 D451590 WORKSHOP MANUAL Plug both ends of the hose Dismount the screwed fittings...

Page 122: ...D451593 12 Screed 12 2 Replacement of linear hydraulic motors for screed extension Remove the hoses Note Place a container under the hoses to trap the oil Avoid the oil soaking into the ground Plug a...

Page 123: ...119 F80W D451594 D451595 WORKSHOP MANUAL Remove the pin Note Proceed in the same way on the other side of the hydraulic motor...

Page 124: ...ke sure that the machine is levelled by measuring the frame distance from the ground 12 5 cm at the front wheel Check that the paving cross gradient is on the 0 position If a different distance is mea...

Page 125: ...451606 47 47 451092 DD451035 WORKSHOP MANUAL Start the engine and lower the screed to the ground by selector switch 7 Set the distance of 13 13 5 cm from the ground to the screw centre by the paving t...

Page 126: ...D451036 12 Screed Using the adjusting nuts set the height of the hydraulic exten sion to 2 mm above the main screed Lock the screws 3x Loosen the screws 3x Note Ensure that the paving thickness contro...

Page 127: ...F80W D451066 1 D451067 2 D451068 3 D451069 4 WORKSHOP MANUAL 12 4 Replacement of the friction plates Description 1 Central base plate 1x 2 Central cover plate 1x 3 Rear base plate 2x 2x Rear cover pla...

Page 128: ...1 D451072 Fill the slots with welding Remove the excess weld The plan must be smoothand flat D451075 4 20 12 Screed 12 4 1 Front frame Preparation Weld the central cover plate 2 to the central base pl...

Page 129: ...125 F80W D451073 D451074 16 mm D451076 16 mm D451077 WORKSHOP MANUAL Remove the central base plate Install the new base plate Check the dimensions The base plate must be centred...

Page 130: ...126 F80W a3 275 a3 175 a3 50 D451079 D451080 330 D451081 10 40 3 5 25 3 5 50 3 5 25 10 40 a3 275 a3 175 a3 50 D451078 12 Screed Weld the base plate to the frame...

Page 131: ...with welding Remove the excess weld The plan must be smooth and flat D451083 D451084 D451085 D451086 D451087 WORKSHOP MANUAL 12 4 2 Rear frames Preparation Weld the rear cover plate 2x 4 to the rear...

Page 132: ...128 F80W D451088 D451089 D451090 D451091 12 Screed Remove the rear base plates Install the new rear base plates...

Page 133: ...29 F80W D451092 D451093 D451094 a3 40 a3 50 a3 40 D451095 a3 40 a3 50 a3 40 D451096 320 D451097 320 WORKSHOP MANUAL Check the alignment The base plates must be centred Weld the base plates to the fram...

Page 134: ...130 F80W...

Page 135: ...131 F80W WORKSHOP MANUAL 13 Screed gas heating...

Page 136: ...13 Screed gas heating 13 1 Gas system diagram Legend 1 Screed heating system ignition units 2 Gas supply solenoid valves 3 Spark plugs 4 Cables 5 Cable 6 Gas supply manifold 7 Gas hose 8 Gas hose 9 Ga...

Page 137: ...ture of 120 C on the screed temperature sen sor the heating is automatically interrupted After reducing the screed temperature heating is automatically activated by the control unit If the flame canno...

Page 138: ...e measurement on the cable harness of ignition units 13 9 2 2 The flame is not steadily burning Incorrect gas flame adjustment Proceed according to Chapter 13 7 3 Nozzles are clogged Proceed according...

Page 139: ...tor A gas leak detection spray B soap water Gas equipment tightness check procedure Start the engine Switch on the screed gas heating Check the tightness of the gas equipment e g with a gas leak detec...

Page 140: ...s can easily ignite The machine must be equipped with a fire extinguisher Have the fire extinguisher ready on the driver s stand at a place intended for this purpose Pay extra attention to potential g...

Page 141: ...y discon necter and with the closed gas bottle valve 13 5 Gas hoses Ensure that gas hoses are not damaged In case of their damage replace the hoses and perform a gas leakage test If the gas hose repla...

Page 142: ...138 F80W D451613 D451614 D451615 13 Screed gas heating Loosen the fittings 5x Remove the screws 2x...

Page 143: ...ent of the screed heating burner with the machine with the switched off battery disconnecter and with the closed gas bottle valve Remove the hose Loosen the screw and replace the burner Note When reas...

Page 144: ...ing 13 7 2 Cleaning the gas burner nozzle Perform the cleaning of the gas burner nozzle with the machine with the switched off battery disconnecter and with the closed gas bottle valve Remove the hose...

Page 145: ...141 F80W D451602 D451603 WORKSHOP MANUAL Clean the nozzle hole with a suitable wire...

Page 146: ...ce plant or qualified personnel according to the pro cedure given below Adjust the distance D between the gas burner 3 and the spark plug 4 Adjust the distance D by loosening the gas burner set screw...

Page 147: ...em by moving the switch 13 to the upper position Check that all burners are burning Unless the burners start within a few seconds switch off the gas screed heating system and perform a test of spark p...

Page 148: ...al gas leaks and in doubts shut off the gas supply Check the tightness of the gas equipment e g with a gas leak detector If you detect gas leakage immediately shut off the gas bottle shut off valve an...

Page 149: ...upply solenoid valves 13 8 1 Valve cleanliness inspection Check the cleanliness of the valves with the machine with the switched off battery disconnecter and with the closed gas bot tle valve Remove t...

Page 150: ...Note When reassembling observe the correct placement of the valve so that the arrow on the valve corresponds to the gas flow direc tion 13 8 2 Measuring resistance of the coils of gas supply valve el...

Page 151: ...the key in the ignition box 11 to the I position Switch on the gas screed heating system by changing over the switch 13 to the upper position Measure the battery voltage 12 V on the sockets of electro...

Page 152: ...th disconnected supply cables Measure the resistance of approximately 53 2 between pin 3 and pin of the frame There is an opened circuit between pin 3 and pins 1 and 2 There is an opened circuit betwe...

Page 153: ...ely 2 72V between the pin of the frame and pin 1 Note If a different value is measured check the wiring between ignition units A6 A7 A8 and the control unit A2 the wiring between the pin of the frame...

Page 154: ...gnition box 11 in the position 0 and switch over to the position I Set the key between position I and II and the engine glowing indicator lamp 24 will light up Do not perform engine glowing for more t...

Page 155: ...tween the middle electrode 5 and the external electrode 6 by slightly bending the external electrode 6 Screw in the spark plug 3 Mount the cable of the spark plug 4 Perform the spark plug test again a...

Page 156: ...approximately 1 1 k at the tempera ture of 20 C on the pins of the temperature sensor Measure the voltage of approximately 3 32 V on the pins of the temperature sensor socket Note If a different volta...

Page 157: ...153 F80W WORKSHOP MANUAL 14 Belt conveyors and augers...

Page 158: ...s 14 1 Replacement of the hydraulic motor for driving the augers and the belt conveyor Set the lever for material outlet to the lower position Remove the cover of the drive for belt conveyors and auge...

Page 159: ...155 F80W D421528 D421529 D421530 D421531 WORKSHOP MANUAL Remove the tension screw Remove the screw for fastening the tension mechanism of the auger chain...

Page 160: ...eyors and augers Remove fastening screws of the hydraulic motor 2x Take out the hydraulic motor for driving the belt conveyor and auger Note When reassembling the hydraulic motor of augers and belt co...

Page 161: ...n Dismount the belt conveyor chain from the machine with the switched off battery disconnecter and with the closed gas bot tle valve Replace the belt conveyor chain when the thickness between the chai...

Page 162: ...drive chain of the belt conveyor Remove the screws of the hydraulic motor 2x Loosen the hydraulic motor screws 2x Pull the hydraulic motor slightly out towards you Cut the binding strap of the hose a...

Page 163: ...159 F80W D451543 D451544 D451545 D451546 WORKSHOP MANUAL Remove the screw Remove the screw and the washer Remove the lock ring Remove the gear wheels...

Page 164: ...51537 14 Belt conveyors and augers Loosen the tension screws of the belt conveyor on the left and right side of the machine By moving the belt conveyor find and dismount chain coupling links 2x Take t...

Page 165: ...closed gas bottle valve Insert the chain to the machine and mount the chain coupling links 2x Secure the chain coupling links in the direction of con veyor chain movement from the inner side of the ch...

Page 166: ...y manually turning the chain of the belt conveyor Observe the correct conveyor chain tension according to Chap ter 14 4 Mount the belt conveyor drive chain by proceeding in the re verse order accordin...

Page 167: ...ANUAL Mount the screw Remove the tension screw for the belt conveyor drive and mo tor cover Tighten the hydraulic motor screws 2x Mount the screws of the hydraulic motor 2x Note Secure the screws of t...

Page 168: ...164 F80W D451519 D451518 D451517 14 Belt conveyors and augers Mount the rear wheels on the left and right side of the ma chine...

Page 169: ...rt of the chain 1 and measure the distance between the ground and the chain again Calculate the sag of the chain 1 by deducting the two measured values The chain is correctly tensioned when there is a...

Page 170: ...top the conveyor Turn off the engine Perform tensioning of the conveyor chains with the ma chine parked on a flat and solid surface with the engine and battery disconnecter off Wear the prescribed per...

Page 171: ...onveyor chain drive Dismount the belt conveyor chain drive from the machine with the switched off battery disconnecter and with the closed gas bottle valve Remove the rear wheels on the left and right...

Page 172: ...3 14 Belt conveyors and augers Loosen the hydraulic motor screws 2x Pull the hydraulic motor slightly out towards you Cut the binding strap of the hose Remove the drive cover Remove the tension screw...

Page 173: ...169 F80W D451544 D451545 D451546 WORKSHOP MANUAL Remove the screw and the washer Remove the lock ring Remove the gear wheels with the chain for driving the belt con veyor...

Page 174: ...ismounting the auger chain Dismount the auger chain from the machine with the switched off battery disconnecter and with the closed gas bottle valve Remove the rear wheels on the left side of the mach...

Page 175: ...UAL Remove the cover Remove the hydraulic motor of the augers and the belt convey or according to Chapter 14 1 Remove the belt conveyor chain according to Chapter 14 2 Remove the lock screws Remove th...

Page 176: ...51 D451552 D451553 14 Belt conveyors and augers Remove the bearing housing on the left and right side Take the shaft out Pull out the auger chain Note Proceed in the reverse order when reassembling th...

Page 177: ...switch of augers and belt conveyor Perform the replacement of the drive switch of augers and belt conveyor on the machine with the switched off battery discon necter and with the closed gas bottle val...

Page 178: ...sition Measure the voltage of 9 9 V on the connector on the cable harness side Resistance measurement Disconnect the connector X43 The switch in the ON status the material delivery is active Measure t...

Page 179: ...riving gear wheel of augers from the machine with the switched off battery disconnecter and with the closed gas bottle valve Remove the augers Remove the lock screws Remove the screws on the right and...

Page 180: ...lt conveyor chain guide plate on the machine with the switched off battery disconnecter and with the closed gas bottle valve Remove the rear wheels on the left and right side of the ma chine Remove th...

Page 181: ...1560 D451559 D451558 D451561 WORKSHOP MANUAL Remove the screws 3x Remove the rear shaft with gear wheels Loosen the tension screws on the left and right side Remove the bearing housing on the left and...

Page 182: ...1564 D451565 14 Belt conveyors and augers Pull out the shaft with the gear wheels Remove the front shaft with gear wheels Loosen the screws on both sides of the machine Remove chain tensioners Remove...

Page 183: ...hanism of the front wheel height Take out the guide plate of the belt conveyor chain and replace it with the new one Mount the front shaft and the chain tensioners Mount the rear shaft and the bearing...

Page 184: ...or chain according to Chapter 14 3 Note Ensure that the conveyor chain is installed with the contact sur face to the chain guide plate Ensure that the chain is at the same distance from the machine fr...

Page 185: ...sides of the ma chine Mount the screws 3x Mount the cover plates Mount the screws 8x Note Secure the screws with the LOXEAL 83 54 adhesive Mount the belt conveyor drive chain by proceeding in the re...

Page 186: ...451557 14 Belt conveyors and augers Mount the rear wheels on the left and right side of the machine Mount the screws 14 9 2 Cover plates Remove the screws 8x Note During reverse assembly glue the scre...

Page 187: ...183 F80W WORKSHOP MANUAL 15 Wiring...

Page 188: ...184 F80W D451647 1 2 3 3 3 4 5 15 Wiring 15 1 Description of basic components 1 Main harness 2 Battery cable 3 Gas ignition cable 4 Beacon cable 5 Foot switch cable...

Page 189: ...5 F80W DD451042 X7 X6 DD451043 X7 X6 DD451044 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 WORKSHOP MANUAL 15 1 2 Central earthing points X6 and x7 Location of earthing points Numbering of pi...

Page 190: ...to ground detected check wiring X49 RD 149 WH 238 F21 horn button short circuit to ground detected check wiring X45 RD 145 WH 231 F22 engine start switch short circuit to ground detected check wiring...

Page 191: ...X67 K1 WH 267 BN 329 F53 fuel valve output short circuit to ground or battery or no connection detected check wiring X17 5 WH 205 F54 conveyor low side output short circuit to ground or battery or no...

Page 192: ...ttery or no connection detected check wiring A9 20 X1 1 4 S20 F85 Engine overtemperature Engine temperature is too high let engine run in low idle and open the engine cover F86 Charge control Check po...

Page 193: ...t 25 A F3 Oil cooler fan fuse 15 A F4 Horn and reverse travel with horn fuse 5 A F5 Fuse of beacon and auger area lighting 7 5 A F6 Screed heating fuse 5 A F7 Universal display fuse 2 A F8 Fuse of the...

Page 194: ...190 F80W D451648 1 DD451062 2 15 Wiring 15 2 3 Diagnostics socket Location of the diagnostic socket Basic description of the diagnostic socket 1 CAN Low pin 7 2 CAN High pin 2...

Page 195: ...tic socket of CAN Low pin 1 15 2 3 1 1 Measuring voltage of the CAN BUS data bus Turn the key in the ignition box to the I position Measure a voltage at the range of 2 5 3 5 V at the CAN High output p...

Page 196: ...ans of Bodas service 3 5 To communicate with the control unit Bodas service 3 5 must be installed Components necessary to connect to the machine Bodas service 3 5 software connecting cable and a USB k...

Page 197: ...002 2 D451C004 0 I II 380K0022 WORKSHOP MANUAL Connect the computer to the machine using the connecting cable 1 Connect the USB key 2 to the computer Start the Bodas software Turn the key in the ignit...

Page 198: ...1C006 D451C007 Number of found controllers 0 Scannin for controllers g D451C005 15 Wiring Press the button to confirm licence conditions The computer is connecting Press the Scan icon for connecting t...

Page 199: ...rors If the name of the computer and software version are written in red some errors are active If they are written in black the computer is without errors Unroll the Error Messages tab A list of erro...

Page 200: ...uts of the RC unit There are two ways how to display the values Method No 1 Display the I O Status view tab the check of the voltage level on individual pins Method No 2 Select item 4 Setup Check the...

Page 201: ...ire Turn the key in the ignition box to the I position Measure the voltage of battery 12 V on the connector X33 be tween the wires Measure the voltage of approximately 3 1 V on the connector X40 betwe...

Page 202: ...will be displayed after activating the foot switch Turn the key in the ignition box to the I position Measure the voltage of approximately 9 77 V at the foot switch on the connector X44 between pin A...

Page 203: ...case of a failure of the travel controller error messages F11 F28 F29 or F30 F63 F64 and F65 will be displayed on the dis play Remove the steering wheel Remove the cover Remove the screw Take out the...

Page 204: ...the travel controller set in the forward position 3 1 k between pin 6 and pin 7 with the travel controller set in the neutral position 5 4 k between pin 6 and pin 7 with the travel controller set in t...

Page 205: ...g speed selector on the machine with the switched off battery disconnecter and with the closed gas bot tle valve Remove the paving speed selector Remove the steering wheel Remove the cover Remove the...

Page 206: ...202 F80W D452034 DD451015 DD451016 15 Wiring Remove the paving speed selector regulator Loosen the screw Remove the nut...

Page 207: ...sure the resistance of the paving speed selector 6 2 between pin 1 and pin 3 5 5 between pin 1 and pin 2 in the minimum selector position 0 6 between pin 1 and pin 2 in the maximum selector position 0...

Page 208: ...erform calibration on the machine with the closed gas bottle valve 15 3 1 Connecting the machine to PC Park the machine on a solid and flat surface Connect the computer to the machine using the connec...

Page 209: ...006 WORKSHOP MANUAL Turn the key in the ignition box to the I position 15 3 2 Calibration of the travel controller and the paving speed selector Press the Scan icon for connecting the computer Press t...

Page 210: ...er 1 8 2 driving lever middle 1 8 3 speed poti Minimum Minimum Maximum Maximum 0 67V 3 97V Saved 2 20V 0 62V 4 20V Current Current Current Accept Accept Accept Calibrate Calibrate Calibrate STD STD ST...

Page 211: ...8 1 driving lever 1 8 2 driving lever middle 1 8 3 speed poti D451C012 Minimum Minimum Maximum Maximum 0 57V 3 97V Saved 2 20V 0 62V 4 20V Current Current Current 4 12V Set max value Accept Accept Ca...

Page 212: ...Cancel Calibrate STD STD STD 1 8 Calibration operation 1 8 1 driving lever 1 8 2 driving lever middle 1 8 3 speed poti 451C015 Minimum Minimum Maximum Maximum 0 61V 4 09V Saved 2 24V 0 05V 4 98V Curre...

Page 213: ...t Minimum Maximum 0 61V 4 09V 2 25V Current Current Minimum Maximum 0 55V 4 98V Current 0 55 V Set min value Cancel STD STD STD 1 8 Calibration operation 1 8 1 driving lever 1 8 2 driving lever middle...

Page 214: ...nt 4 29 V Set max value Cancel STD STD STD 1 8 Calibration operation 1 8 1 driving lever 1 8 2 driving lever middle 1 8 3 speed poti D451C022 451C003 D451C023 15 Wiring Confirm it by pressing the Set...

Page 215: ...ill be uploaded Unroll the Parameter tab and select 1 7 Calibration drive Check the last box in 1 7 7 Propel pump calib The line will be come red and the value will be changed to 1 Start the transport...

Page 216: ...value The line will become red and the value will be changed to 1 Uncheck the last box in 1 7 8 Set value A short sound signal will be heard in case of correct setting Shift the drive control 8 to the...

Page 217: ...D452039 WORKSHOP MANUAL Slowly turn the paving speed selector 14 to the max position Confirm the setting by checking and subsequent unchecking the box in 1 7 8 Set value A short sound signal is heard...

Page 218: ...and subsequent unchecking the box in 1 7 8 Set value A short sound signal is heard Activate the foot switch 48 Shift the travel controller 8 to the reverse travel position Slowly turn the paving spee...

Page 219: ...D452040 WORKSHOP MANUAL Slowly turn the paving speed selector 14 to the max position Confirm the setting by checking and subsequent unchecking the box in 1 7 8 Set value A short sound signal is heard...

Page 220: ...89 451C034 15 Wiring Confirm the setting by checking and subsequent unchecking the box in 1 7 8 Set value A short sound signal is heard After finishing calibration uncheck the last box in 1 7 7 Propel...

Page 221: ...1649 1039S92041 SW HW 00D6 415 E1 10 R 056430 BODAS RC28 14 30 S N 00071649 D451064 WORKSHOP MANUAL 15 4 Control unit A2 When replacing the control unit the machine compatibility with the software in...

Page 222: ...218 F80W 1 2 73 01 96 24 05 06 46 01 02 07 19 58 D451065 15 Wiring 15 4 1 Connector of the control unit Description of the connector 1 Connector X34 2 Connector X35 X34 Pin 101 194 X35 Pin 201 258...

Page 223: ...4 2 Dismounting the control unit A2 Dismount the control unit from the machine with the switched off battery disconnecter and with the closed gas bottle valve Unlock and disconnect connectors X34 and...

Page 224: ...splay connector X33 pin 1 wiring between the battery disconnecter and the connector X33 pin 5 connection of connectors X33 and X40 to the display 15 5 1 Dismounting the display Dismount the display fr...

Page 225: ...221 F80W D452047 DD451005 WORKSHOP MANUAL Remove the plate on the control panel Remove the screws 3x Remove the lock nuts 2x Note Proceed in the reverse order when reassembling the display...

Page 226: ...d according to Chapter 15 3 2 15 6 1 Dismounting the travel controller A4 Dismount the travel controller from the machine with the switched off battery disconnecter and with the closed gas bottle valv...

Page 227: ...he plate on the control panel Remove the screws 3x Disconnect the connector X36 Remove screws of the travel controller 4x Note Proceed in the reverse order when reassembling the unit After reassemblin...

Page 228: ...d selector proceed accord ing to Chapter 15 3 2 15 7 1 Dismounting the paving speed selector Dismount the paving speed selector from the machine with the switched off battery disconnecter and with the...

Page 229: ...he paving speed selector regulator Loosen the screw Remove the nut Slightly pull out the selector and disconnect the X37 connector Note Proceed in the reverse order when reassembling the unit After re...

Page 230: ...Wiring 15 8 Battery Measuring the battery voltage Battery status Battery voltage Battery charge status 12 6 V 100 12 5 V 90 12 42 V 80 12 32 V 70 12 20 V 60 12 06 V 50 11 9 V 40 11 75 V 30 11 58 V 20...

Page 231: ...227 F80W WORKSHOP MANUAL 16 Appendices...

Page 232: ...n button S10 Left smoothing screed extension switch S11 Right smoothing screed extension switch S12 Smoothing screed lifting switch S13 Vibration switch S14 Smoothing screed heating switch S15 Conveyo...

Page 233: ...2 1 3 4 A1 55 56 11 13 N C N C 28 42 GND 43 8 14 BAT 15 27 47 CAN 0 L 48 CAN 0 H 2 2 2 3 2 1 2 1 2 2 X17 1 X34 62 162 X34 63 163 K1 31 K1 30 CAN 3 L CAN 3 H 7 2 X9 3 X9 4 X34 89 189 X34 90 190 B C D P...

Page 234: ...thing screed extension switch S12 Smoothing screed lifting switch S13 Vibration switch S14 Smoothing screed heating switch S15 Conveyor direction switch S16 Automatic mode switch S17 Operating mode sw...

Page 235: ...7 15 X35 41 241 X34 3 103 X35 43 243 X34 49 149 7 5A 30 87 87a 85 86 X7 16 X23 1 X23 2 X6 4 X6 5 X34 94 194 X35 53 253 X35 54 254 X35 40 240 GND 5V X34 21 121 X34 45 145 X35 15 215 X35 16 216 2 3 X35...

Page 236: ...thing screed extension switch S12 Smoothing screed lifting switch S13 Vibration switch S14 Smoothing screed heating switch S15 Conveyor direction switch S16 Automatic mode switch S17 Operating mode sw...

Page 237: ...6 6 X6 15 3 X6 8 3 X6 10 3 X6 12 X73 1 X76 1 X74 1 X77 1 X75 1 X78 1 2A X33 1 X33 5 X40 6 X40 7 120 120 X6 13 30 87 87a 86 85 30 87 87a 86 85 1 4 2 1 4 2 1 4 2 H L A F6 B C Y14 Y15 A6 D A7 E A8 F I1 I...

Page 238: ...234 F80W 16 Appendices 16 2 Electric installations cable harnesses 1 Main harness 40744...

Page 239: ...5 1 0 BN 1 317 317 WH 1 210 110 WH 1 102 2 5 2 5 2 5 1 1 2 1 3 1 WH 1 211 2 5 2 5 1 2 2 2 2 5 3 2 50 2 1 MATE N LOK A3 X33 3 172171 1 5 4 6 8 7 9 11 10 12 14 13 15 2 1 MATE N LOK A3 40 3 794196 1 5 4...

Page 240: ...sh language version 1 Travel pump 2 Operating pump 3 Left travel motor 4 Right travel motor 5 Suction return filter 6 Hydraulic oil cooler 7 Hydraulic system block 8 Augers 9 Screed lifting lowering h...

Page 241: ...237 F80W WORKSHOP MANUAL 451190...

Page 242: ...the workshop manual delivered upon a special order Mode Pressure bar Measuring point no 1 Conveyor maximum speed 150 5 Auger maximum speed 150 4 Screed lifting maximum speed 50 5 Screed extension max...

Page 243: ...OP MANUAL 16 4 Screed gas heating system diagram Legend 1 Automatic screed heating ignition boxes 2 Gas supply solenoid valves 3 Spark plugs 4 Cables 5 Cable 6 Gas supply manifold 7 Gas hose 8 Gas hos...

Page 244: ...240 F80W 16 Appendices Notes...

Page 245: ......

Page 246: ...www dynapac com...

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