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F80

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tz

www.dynapac.com

WORKSHOP MANUAL

WORKSHOP MANUAL

Asphalt paver wheeled
F80W
Hatz

4812077915

Poznámka: Laminace lesklá 1+1 (oboustranná), horizontální a vertikální ořez dle ořezových značek, 2x big - 205 mm vnější a 210 mm vnitřní od okraje čistého formátu, dodávka obálek v přeloženém a baleném stavu po jednotlivých typech.

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Содержание Hatz F80W

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

Страница 2: ......

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

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 10: ...6 F80W...

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

Страница 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...

Страница 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...

Страница 14: ...10 F80W...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 26: ...22 F80W...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 36: ...32 F80W...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 42: ...38 F80W...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 80: ...76 F80W...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 96: ...92 F80W...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 110: ...106 F80W...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 118: ...114 F80W...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 134: ...130 F80W...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 245: ......

Страница 246: ...www dynapac com...

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