DYNAPAC Paver finisher F 121 C, F 141 C Type 635. Operation & Maintenance (Order number: 4812026925)

Malfunctions

2.1

Problems during paving

Problem

Cause:

change in the material temperature, demixing

wrong material composition

incorrect operation of the roller

incorrectly prepared foundation

long standstill times between loads

grade control reference line is not suitable

grade control jumps to the reference line

grade control toggles between up and down

Wavy surface

(inertia setting is too high)

(”short waves”)

bottom plates of the screed are loose

bottom plates of the screed are warped or not uniformly

worn

screed does not work in the floating position

too much play in the mechanical screed link/suspension

paver finisher speed is too high

augers are overloaded

changing material pressure against the screed

change in the material temperature

demixing

roller has stopped on the hot material

roller has turned or roller speed has been changed too fast

incorrect operation of the roller

incorrectly prepared foundation

truck brake is applied too tight

long standstill times between loads

Wavy surface

grade control reference line is not suitable

(”long waves”)

incorrect installation of the grade control

limit switch is not correctly set

screed is empty

screed has not been switched to the floating position

too much play in the mechanical screed link

auger is set too deep

auger is overloaded

changing material pressure against the screed

material temperature is too low

change in the material temperature

moisture on the foundation

Cracks in the layer

demixing

(over the entire

wrong material composition

width)

wrong layer height for the maximum grain size

cold screed

bottom plates of the screed are worn or warped

paver finisher speed is too high

temperature of the material

Cracks in the layer

cold screed

(center strip)

bottom plates are worn or warped

wrong crowning

D4.1 23

Problem

Cause:

temperature of the material

screed extendable parts are incorrectly installed

Cracks in the layer

limit switch is not correctly set

(outer strip)

cold screed

bottom plates are worn or warped

paver finisher speed is too high

temperature of the material

change in the material temperature

moisture on the foundation

demixing

wrong material composition

incorrectly prepared foundation

wrong layer height for the maximum grain size

Layer composition is

long standstill times between loads

not uniform

vibration is too slow

screed extendable parts are incorrectly installed

cold screed

bottom plates are worn or warped

screed does not work in the floating position

paver finisher speed is too high

auger is overloaded

changing material pressure against the screed

truck hits too much against the paver finisher while aligning

to the paver finisher

Marks in the surface

too much play in the mechanical screed link/suspension

truck brake is applied

vibration is too high while standing on a spot

temperature of the material

change in the material temperature

Screed does not re-

wrong layer height for maximum grain size

act to corrective

incorrect installation of the grade control

measures as expect-

vibration is too slow

screed does not work in the floating position

too much play in the mechanical screed link

paver finisher speed is too high

D4.1 24

2.2

Malfunctions on the paver finisher or screed

Malfunction

Cause:

Remedy

See operating instructions for

At the diesel engine

Diverse

the engine

See ”External starting”

Diesel engine does

Batteries empty

(start assistance)

not start

Diverse

see ”Towing”

Tamper is obstructed by

Properly heat the screed

cold bitumen

Hydraulic oil level in the

Top up the oil

tank is too low

Pressure limiting valve is

Replace the valve; if necessary,

Tamper or vibration

defective

repair and adjust the valve

does not operate

Seal or replace the connections

Leak in the suction line of

Tighten or replace the hose

the pump

clamps

Clean the filter; if necessary,

Oil filter is soiled

replace the filter

Hydraulic oil level in the

Top up the oil

tank is too low.

Check fuses and cables; replace

Power supply is interrupted

if necessary

Switch is defective

Replace the switch

One of the pressure limiting

Repair or exchange the valves

Conveyor or augers

valves is defective

run too slowly

Pump shaft broken

Replace the pump

Limit switch does not switch

Check the switch; replace and

or regulate correctly

adjust the switch if necessary

Check the high pressure filter for

Pump is defective

dirt particles; replace if

necessary

Oil filter is soiled

Replace the filter

Engine speed is too low

Increase the speed

Hydraulic oil level is too low

Top up the oil

Leak in the suction line

Tighten the connections

Flow rate regulator

Replace

Hopper cannot be

defective

swung open

Leaking seals of the

Replace

hydraulic cylinder

Control valve is defective

Replace

Check fuse and cables; replace

Power supply interrupted

if necessary

D4.1 25

Malfunction

Cause:

Remedy

Control valve is defective

Replace

Hoppers lowers

Leaking seals of the

inadvertently

Replace

hydraulic cylinder

Oil pressure too low

Increase the oil pressure

Leaking seal

Replace

Screed cannot be

Screed relieving or

Switch must be in the center

lifted

charging is switched on

position

Check fuse and cables; replace

Power supply is interrupted

if necessary

Switch on the remote

Set the switch to ”manual”

control is set to ”auto”

Check fuse and cables; replace

Power supply is interrupted

if necessary

Switch on the operating

Crossbeams cannot

Replace

panel defective

be lifted or lowered

Excess pressure valve

Replace

defective

Flow rate regulator

Replace

defective

Seals defective

Replace

Control valves defective

Replace

Crossbeams lower

Pilot-controlled non-return

Replace

inadvertently

valves defective

Seals defective

Replace

D4.1 26

Malfunction

Cause:

Remedy

Replace

Traction drive fuse

(Fuse holder on the operating

defective

panel)

Check potentiometer, cables,

Power supply is interrupted

connectors; replace if necessary

Traction drive monitoring

Replace

(type-specific) defective

Traction does not

Electro-hydraulic servo unit

work

Replace the servo unit

of the pump defective

Check and adjust if necessary

Check the suction filter; replace

Insufficient supply pressure

the supply pump and the filter if

necessary

Drive shaft of hydraulic

Replace pump or engine

pumps or engines broken

Check the fuel level; refill fuel if

Fuel level too low

necessary

Irregular engine

Replace

Fuse ”engine speed

speed, engine stop

(fuse strip on the operating

control” defective

function does not

panel)

work

Defective power supply

Check potentiometer, cables,

cables (cables broken or

connectors; replace if necessary

short-circuited)

D4.1 27

Emergency device/steering, drive system

In case of a malfunction in the electronic drive system it is possible to override the

system by an emergency device. This emergency device is included in the tool set of

every crawler machine.

To install the emergency device all plugs of the drive pump servo valves have to be

replaced by the plugs of the emergency device. (short screw driver is necessary.)

The cable shoe is connected to power supply of 24 Volts and the cable eye is con-

nected to ground.

The plug of the hydraulic brake valve is replaced by the corresponding plug of the

emergency device.

Voltage supply can be provided through a 24V connection plug.

The control unit is fastened on the operating panel.

To connect the plugs follow to the wiring diagram on the following page.

D4.1 28

Following functions are located in the steering unit:

No.

Denomination

Mounting screws for holder plate

Switch for preselection of the zero position and forward reverse movement

Adjustment knob for speed control (Replace speed preselector)

Steering knob

Switch to turn the paver finisher on the spot

Function

If the emergency device is connected all functions like engine speed, conveyor, au-

ger, tamper and vibration have to be controlled by the forward reverse lever.

Starting up for laying

- Preselect the speed with turning knob (3)

- Push switch (2) in forward direction

- Engage forward reverse lever like under normal conditions

- All other functions (4, 5) have to be in the position described in the instruction man-

ual (Operation)

Transport

- Adjust turning knob (3) to a low speed

- Push switch (2) to the recommended direction and engage the forward reverse le-

ver to forward direction.

- If the recommended direction is reverse push switch in reverse, but still the forward

reverse lever should be moved to forward direction

- Adjust the driving speed with turning knob (3)

- All other functions have to be in the position described in the instruction manual

(Operation)

When starting the engine, switch (2) must be in the zero position since the machine

would otherwise move off straightaway! Risk of accident!

D4.1 29

E 01

Set-up and modification

Special notes on safety

Danger to personnel by inadvertent starting of the engine, the traction drive, the con-

veyor, the auger, the screed or the lifting units. Unless specified otherwise, work may

only be performed when the engine is at a standstill!

- To protect the paver finisher against inadvertent starting:

Set the drive lever to the center position and set the preselector to zero; if applica-

ble, remove the drive traction fuse from the operating panel; pull out the ignition key

and the battery main switch.

- Secure lifted machine parts (e.g. screed or hopper) against lowering by means of

mechanical supports.

- Replace parts or have them replaced as stipulated.

When connecting or disconnecting hydraulic hoses and when working on the hydrau-

lic system, hot hydraulic fluid can spurt out at a high pressure.

Switch off the engine and de-pressurize the hydraulic system! Protect your eyes!

- Mount all protective devices before re-commissioning the paver finisher.

- The walking platform must always reach over the entire width of the screed. The

hinged walkway (option for all variable screeds) may only be swung up under the

following circumstances:

- When paving next to a wall or a similar obstacle.

- During transportation on a low-bed trailer.

E 01 1

Auger

2.1

Height adjustment

Depending on the mix of materials,

when working with layer thicknesses of

up to 15 cm, the height of the distribution

auger (1) - measured from its bottom

edge

- should be around

5 cm

(2 inches) above the material layer thick-

ness (depending on its mix of materials).

Example: Layer height 10 cm

Adjustment: 15 cm from the

F0130_A1.TIF

ground

An incorrect height adjustment can result in the following problems:

- Auger too high:

Too much material in front of the screed; material overflow. When operating with

larger widths, demixing and traction problems may occur.

- Auger too low:

Not enough material that can be precompacted by the auger. Irregularities resulting

from this cannot be completely compensated for by the screed (wavy surface).

In addition, an increased wear on the auger segments occurs.

2.2

Auger crossbeam installed in a fixed

position

- Lower the screed onto a suitable sup-

port (e.g. squared timbers).

- Completely extend both levelling cylin-

ders.

- Hook lifting chains (2) for lifting the au-

ger crossbeam into the hooks of the

F0131_A1.TIF

crossbeams.

- Loosen the fixing screws (3) of the auger crossbeam.

- Retract the levelling cylinders until the

auger crossbeam has reached the de-

sired height.

- Tighten the fixing screws (3) of the au-

ger crossbeam.

F129_A1.TIF

E 01 2

2.3

Mechanical adjustment with ratchet

(optional)

- Set the ratchet direction lever to clock-

wise or anticlockwise direction. Turn-

ing anticlockwise lowers the auger,

turning clockwise lifts the auger.

- Set the desired height by alternatingly

adjusting the right-hand and the left-

hand side.

- The actual height can be read on scale

(1) in cm or inch (LH side column:

inch, RH side column: inch).

F0116_A1.EPS

2.4

In case of hydraulic adjustment (op-

tion)

- Determine the currently set height of

the auger crossbeam (left and right)

by means of the scale (1).

F0117_A1.EPS

E 01 3

2.5

Auger extension, auger type I

Auger_Dyn.bmp

Depending on the type of screed, the most diversified working widths can be reached.

A Auger and screed extension must match. See the operating instructions of the appro-

priate screed, chapter ”Set-up and modification”, especially:

- Screed extension chart,

- Auger extension chart.

To attain the desired working width, the respective screed extensions, side plates, au-

gers, tunnel plates or cut-off shoes must be mounted.

For widths of more than 3.00 m, the auger should be fitted with extension parts on

both sides to improve material distribution and to reduce the wear.

f The diesel engine must be switched off whenever work is performed on the auger.

Danger of injuries!

E 01 5

2.6

Mounting extension parts

- Loosen the clamping screws (6) on

the support tube. Then turn in the

center expanding screw (5) to expand

the clamping joint.

F132_A1.TIF

- Pull the telescopic tube out of the sup-

port tube (7).

- Mount the required extension parts.

Observe the guide groove of the spline!

Make sure that the shaft end is clean!

- Slide in the telescopic tube. When do-

ing so, make sure that the drive of the

auger gear is slid all the way over the

shaft end of the auger extension part

F0133_A1.TIF

and that the threads of the augers

match.

- Remove the expansion screw (5). Then tighten the clamping screws (6). Finally

tighten the expansion screw by hand.

Before the clamping screws (6) can be tightened again, the expansion screw (5) must

be sufficiently turned back!

Otherwise, the telescopic tube cannot be safely clamped and the splined shaft ends

break.

When clamped insufficiently, the telescopic tube can slide out of the support tube.

Danger of accidents during transportation!

E 01 6

2.7

Mounting support tube extensions

If the working width exceeds 7.25 m, an

auger crossbeam extension must be

mounted.

The support tube extension of the auger

crossbeam consists of two halves (8)

and is attached to the existing support

tube by using a total of 5 screws. After

the two halves have been screwed to the

support tube, they also must be linked to

F0134_A1.TIF

each other by means of screwed con-

nections.

Clamping of the telescopic tube occurs

by tightening the screwed connections

(9) linking the support tube extension.

F0136_A1.TIF

If the working width exceeds 7.50 m the

hydraulic hoses (10) for the auger mo-

tors must be replaced with longer ones.

These long hoses are included in the

scope of delivery for this working width.

f When connecting or disconnecting hy-

draulic hoses, hydraulic fluid can spurt

out at a high pressure.

Switch off the paver finisher and de-

pressurize the hydraulic circuit! Protect

your eyes!

m When installing the hoses, make sure

F0135_A1.TIF

that the area around the connections is

clean.

Any dirt that enters the hydraulic system can cause malfunctions.

E 01 7

2.8

Installing tunnel plates

To ensure an optimum material flow -

especially in the case of large paving

widths

- so-called tunnel plates

(11)

must be installed.

They are located directly in front of the

auger distributor and - in conjunction

with the auger - are an ideal system for

conveying the material.

When operating with widths of more

than 3.90 m, two or more combined tun-

F0140_A1.TIF

nel plates (13) must be used.

In this case, additional stabilizing sup-

ports (12) must be attached to the tele-

scopic tube.

The tunnel plates must be directly

screwed to the receptacles provided for

this purpose (14); they are located on

the auger frame sides and can thus be

adjusted in height.

Refer to the auger extension chart to de-

termine which parts of the conveyor sys-

tem are required for the desired paving

width.

The auger extension chart is contained

in the operating instructions for the re-

spective screed.

F0139_A1.TIF

E 01 8

2.9

Installing additional braces

When operating with width of more than

7.25 m the augers must be provided with

an additional support.

F0141_A1.TIF

To do so, attach two braces on both the

left-hand and the right-hand side, be-

tween the tunnel plate support and the

bracket provided on the paver finisher.

The braces are included in the scope of

delivery for this working width.

F0142_A1.TIF

E 01 9

- Lock the material shaft (5) with bolts (6), washers (7) and nuts (8) to the basic de-

vice.

- The material shaft can be adjusted in order to match the existing shaft.

- Loosen the nuts (9) for this and turn the sleeve (10) of bolt (6).

- Mount the extension of the auger shaft (11) on the auger shaft of the basic device.

- Fasten the auger segments (12) using bolts (13), washers (14) and nuts (15) for the

extension of the auger and simultaneously bolt the auger shafts firmly together.

A If the application conditions on the job-site allow or demand auger extension, by all

means dismount the external bearing of the auger (16), if the auger extension is long-

er than 600 mm.

When extending the auger on the basic device with external auger bearing, the short-

er auger segment shall be mounted on the bearing. In the opposite case, both the au-

ger segment and the bearing may get damaged, when paving with 30 mm aggregate.

E 01 14

Screed

The operating instructions for the screed cover all work required for mounting, setting

up and extending the screed.

Electrical connections

Establish the following connections when the mechanical components have been

mounted and set up:

5.1

Remote controls

to socket (15) (on the screed).

Socket.bmp

5.2

Grade control

to socket (16) (on the remote control

unit)

5.3

Auger limit switches

to socket (17) (on the remote control

unit)

F0119_A1.TIF

5.4

Working lights

to sockets (18) (on the paver finisher).

F0124_A1.TIF

E 01 17

F 1.0

Maintenance

Notes regarding safety

Maintenance work: Maintenance work may only be carried out when the engine is

at a standstill.

Secure the paver finisher and the attachments against inadvertent starting before be-

ginning any maintenance work:

- Set the drive lever to the center position and the speed preselector to zero.

- Remove the ignition key and the battery main switch.

Lifting and jacking up: Secure lifted machine parts (e.g. screed or hopper) against

lowering by means of mechanical supports.

Spare parts: Use only approved parts and install them according to the specifica-

tions! If in doubt, contact the manufacturer!

Re-commissioning: Mount all protective devices before re-commissioning the paver

finisher.

Cleaning: Cleaning must not be carried out while the engine is running.

Do not use any inflammable substances (such as petrol).

Avoid directly cleaning electrical parts and insulation material with a steam jet; cover

them up beforehand.

Working in closed environments: Exhaust fumes must be led into the open. Pro-

pane gas bottles must not be stored in closed rooms.

In addition to these Maintenance Instructions, the Maintenance Instructions of the en-

gine manufacturer must always also be observed. All other maintenance work and in-

tervals noted in these instructions are also binding.

The instructions for the maintenance of the optional equipment are included in the

sub-chapters of this chapter.

F 1.0 1

Maintenance required after the

following service hours.

Sub-units

Chapter

Feeder

Auger

F4.2

Drive engine

F5.1

Hydraulics

F6.0

Track

F7.1

Electronics

Lubrication points

Checking/stopping

F10

Maintenance required

A This review also includes the maintenance intervals of the optional equipment of the

machine!

F 2.4 2

1.2

Points of maintenance

Chain tightness of the conveyor (1)

Checking the chain tightness:

For daily inspection look straight through

under the bumper. The chain must not

hang below the bottom edge of the bumper.

Should readjustment be necessary, measure the slack unladen from the bottom edge

of the floor plate until the lower edge of the chain (see the figure).

The chains should not be too tight or too

slack. Material between the chains and

the sprocket wheel can lead to stoppage

280

or breakage, in case of too tight chains.

If the chain is too slack, it may get stuck

F0159_A1.TIF

in the protruding objects and be dam-

aged.

Adjustment of chain tightness:

The chain tightness can be adjusted with

grease press. The filling ports (A) are lo-

cated behind the bumper on the RH and

LH sides.

Conveyor_set.eps

F 3.0 3

The drive of conveyor (to the left/to

the right) (2)

The drive unit of the conveyor is under

the floorboard of the operating position.

Checking the oil level Only before the

work starts. The oil level must reach the upper notch of the dipstick (A).

Filling in the oil: After removing cover lid (B) through fill-in stub (C).

On the dipstick about

10 cm corre-

sponds to about 0,25 l oil to be added.

The drive of the conveyor is filled in the

factory with Optimol Optigear 220 oil.

Owing to the excellent quality of the oil

filled in, there is no need for regular oil

change.

It is sufficient to regularly check the oil

level in the drive (see chapter of mainte-

nance intervals).

The above applies only if Optimol Op-

tigear 220 or oil of a similar quality from

another manufacturer is used.

F0151_A1.TIF/F0152_A1.TIF

F 3.0 4

1.2

Points of maintenance

Auger - outer bearing (1)

The grease nipples (A) are located on

each side on the top of outer bearing.

These nipples must be lubricated each

time when work is finished.

A The outer bearings of the auger shall be

lubricated when hot, so that the eventual

bitumen residues are expelled.

Schneckaula_Dyn.tif

Auger middle bearing (2)

Lubrication of central bearing (A) is per-

formed on the LH-side of the auger.

To do so, the bevel gear unit must be

pulled off.

A The central bearing shall be lubricated

when hot, so that the eventual bitumen

residues are expelled.

F0015_A1.TIF

F 4.2 3

Auger bevel gear (on the RH and LH

sides) (4)

- For checking the oil level unscrew

the inspection / filling plug (A).

In case of proper oil level, the oil is at the

lower edge of the inspection port or a lit-

tle oil flows from the hole.

For filling in the oil:

- Remove the inspection / filling plug

(A).

- Fill oil of the correct specification

through the filling hole (A) until the oil

level reaches the lower edge of the in-

spection hole (A).

- Replace the inspection / filling plug

(A).

For changing the oil:

Change the oil when the engine is at op-

erating temperature.

- Remove the inspection / filling plug (A)

and the drain plug (B).

F0139_A1.TIF

- Drain the oil.

- Drive in the oil drain plug (C) again.

- Fill oil of the correct specification through the filling hole (A) until the oil level reach-

es the lower edge of the inspection hole (A).

- Replace the inspection / filling plug (A).

Take care of cleanliness!

F 4.2 5

DYNAPAC Paver finisher F 121 C, F 141 C Type 635. Operation & Maintenance (Order number: 4812026925) - page 5