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

1.1

Maintenance intervals

Interval

Points of maintenance

Remark

Fuel tank

Check the filling level

Fuel tank

Refill with fuel

Fuel tank

Clean the tank and device

Engine lube-oil system

oil level check

Engine lube-oil system

topping up the oil

Engine lube-oil system

oil change

Engine lube-oil system

oil filter change

Engine fuel system

Fuel filter (drain the water separa-

tor)

Engine fuel system

replacement of the fuel pre-filter

Engine fuel system

replacement of the fuel filter

Engine fuel system

bleeding of fuel system

Maintenance

Maintenance during run-in period

F 5.1 2

Interval

Points of maintenance

Remark

Engine air filter

checking of air filter

Engine air filter

dust collecting bin emptying

Engine air filter

Clean / Replace the filter car-

tridge

Cooling system of the engine

Inspection of radiator fins

Cooling system of the engine

Cleaning of the radiator fins

Cooling system of the engine

Check the level of the coolant.

Cooling system of the engine

topping up the coolant

Cooling system of the engine

changing the coolant

Cooling system of the engine

Inspection of coolant

(additive concentration)

Engine drive belt

checking of drive belt

Engine drive belt

tightening of drive belt

Engine exhaust system

(o)

checking of particle filter

Engine exhaust system

(o)

cleaning of particle filter

Maintenance

Maintenance during run-in period

F 5.1 3

1.2

Points of maintenance

Engine fuel tank (1)

- Check the filling level on the gauge

on the operating panel.

A Fill the fuel tank before each start of

work so that the fuel system cannot „run

dry“ and this way the time consuming

venting (bleeding) can be avoided.

For filling in the fuel:

- Unscrew cap (A) (under the tank cov-

er).

- Fill in fuel through the filling port until

the required filling is achieved.

- Replace the cap (A).

Cleaning of tank and device:

- Unscrew the plug (B) at the bottom of

the tank and drain into a collection pan

about 1 lit fuel.

- After drainage screw back the plug

with a new seal ring.

Dieseltank.eps/HDieseltank_bot.bmp

F 5.1 4

Engine lube-oil system (2)

Checking the oil level

In case of correct oil level, the oil is be-

tween the two notches of the dipstick

(A).

Check the oil level with a paver finisher

standing on a flat area!

If there is too much oil in the engine, the

gaskets and seals may get damaged,

while too little oil can lead to the over-

heating of the oil and the damage of the

engine.

For filling in the oil:

- Remove cap (B).

- Fill in oil until the correct level is

achieved.

- Return cap (B).

- Check the oil level once again using

the dipstick.

Oil change:

Change the oil when the engine is at op-

erating temperature.

- Remove the cover cap of the oil drain

port (C) and screw on the hose provid-

ed as an accessory.

- Place the end of the hose in a dish to

catch the oil.

- Open the shutoff valve with a spanner

and let the oil fully drain.

- Shut off the valve, remove the hose

and return the cover cap.

- Fill in the oil of specified quality

through the filling port on the engine

F0112_A1.bmp

until the oil level rises to the correct

mark of the dipstick (A).

F 5.1 5

Changing the oil filter:

A As part of the oil change mount the new filter after the used oil was drained.

- Untighten the filter (D) and clean its resting surface.

- Apply thin coat of oil to the seal of the new filter and fill the filter with oil before

mounting.

- Tighten the filter by hand.

A After mounting the oil filter check the oil pressure gauge and the proper tightness dur-

ing the trial operation. Check the oil level once again.

F 5.1 6

Engine fuel system (3)

A The fuel filter system consists of three fil-

ters:

- Pre-filter (A) with water separator

- Two main filters (B)

A Depending on the machine, the pre-filter

is in the engine compartment or under

the tank lid!

Pre-filter - draining of water

A Empty the collection bin by the specified

intervals or when the engine electronic

indicates a fault.

- Drain the separated water at the tap (C), collect it, and close the tap again.

Change of pre-filter:

- Drain the separated water at the tap

(C), collect it, and close the tap again.

- Pull down the connection of the water

detector (D)

- Untighten the filter cartridge (A) with

the collection sump using a pair of oil

filter tongs or oil filter strap and un-

screw

it.

- Unscrew the collection sump (E) from

the filter cartridge and clean as re-

quired.

- Clean

the sealing surface of the filter

holder.

- Apply a thin coat of oil to the gasket of

the collection sump, drive it under the

filter cartridge and tighten by hand.

- Apply a thin coat of oil to the gasket of

the filter cartridges, drive them under

the holder and tighten by hand.

- Replace the connection of the water

detector (D)

F 5.1 7

Replacement of the main filter:

- Untighten the filter (B) and clean its resting surface.

- Apply a thin coat of oil to the gasket of the new filter.

- Tighten the filter by hand.

A After mounting the filter check for proper tightness during the trial run.

Venting the filter:

- Release the bayonet-mount of the manual fuel pump (F) by pressing and twisting

counter-clockwise at the same time.

- The pump piston now can be displaced by a spring.

- Until strong resistance is felt and the pump moves already very slowly.

- Keep on pumping a few times. (Fill the return pipelines).

- Start the engine and run it for about 5 minutes at idling speed or under a slight load.

- Check the tightness of the pre-filter in the meantime.

- Close the bayonet-mount of the manual fuel pump (F) by pressing and twisting

clockwise at the same time.

F 5.1 8

Engine air filter (4)

Emptying the dust collection bin

- Empty the dust collection valve (B) on

the air cleaner housing (A) by pressing

the discharge port in the direction of

the arrow.

- Discharge the eventually compacted

dust by pressing together the upper

part of the valve.

Clean the discharge port from time to

time.

Cleaning / replacement of the air filter

cartridge

Pollution

of the filter of the combustion

air depends on the dust content of the air

and the mesh size of the filter selected.

The maintenance of the filter becomes

necessary if:

- The maintenance indicator

(O) red

servicing field (C) is fully visible when

the engine is stopped.

- When the engine electronic unit indi-

cates service need

- Open the air filter lid.

- Withdraw the filter cartridge (C) and the safety cartridge (D)

A Clean the filter cartridge (C) and replace min. after one year.

- Blow out with dry pressure air (max. 5 bar) from inside out or tap it (in case of emer-

gency only).

A The cartridges should not get damaged in the process.

- Check the soundness of the filter papers of the filter cartridge (by exposing to light)

and the soundness of the seals. Replace them as required.

A Replace the safety cartridge (D) after 5 filter maintenance, but min. after 2 years (nev-

er clean it!).

After completing the maintenance works:

- Press the reset button (E) of the maintenance indicator (O). The maintenance indi-

cator is ready for operation once again.

F 5.1 9

Coolant system of the engine (5)

Checking / topping up of coolant

The coolant level is checked when the

engine is cold. Make sure that the anti-

freeze and anti-corrosive liquid us suffi-

cient (-25 °C).

When hot, the system is under pressure.

When opening, there is a danger of

scalding!

- If necessary fill in sufficient amount of

coolant through the open port (A) of

the compensating tank.

Changing the coolant

See operating instructions for the engine

Checking and cleaning of the radiator

fins

- If necessary, remove leaves, dust or

sand from the radiator.

Engine drive belt (6)

Checking of drive belt/replacement

A See operating instructions for the engine

F 5.1 10

Engine exhaust system (7)

Cleaning of particle filter

As considerable amount of soot is accu-

mulated in the filter, the cleaning must

be performed under appropriate exhaust

system.

Clean the filter element removed with

oil-free and grease-free pressure air!

- Marking the flow of direction of the ex-

haust gas on the filter case.

- Remove the filter element by untight-

ening the two clips (a).

- First blow out the inlet side.

The pressure of the compressed air can

be max. 5 bars and the nozzle shall not

be closer to the filter edge than 10 cm.

- Carefully blow out all the filter passag-

es.

Partikelfilter.eps

- Turn around the filter element, and re-

peat the process on the other side as

well.

- Repeat the process until no more carbon residue leaves the filter.

- Replace the filter element, taking care of the proper direction of flow.

After cleaning for a short while more soot discharge is expected during operation.

- In case of sticky, oily soot the filter must be heated to about 450°C and the cleaning

shall be carried out preferably with the hot filter.

The filter shall not be cleaned with water/steam or detergent in any case!

The carbon particles are harmful to your health! In case of filter change or cleaning,

wear appropriate protection gear!

F 5.1 11

1.1

Maintenance intervals

Interval

Points of maintenance

Remark

Hydraulic oil tank

Check the filling level

Hydraulic oil tank

Top up with oil

Hydraulic oil tank

oil change and cleaning

Hydraulic oil tank

Checking of maintenance indica-

tor

Hydraulic oil tank

Intake / return

change of hydraulic filter, venting

High pressure filter

Checking of maintenance indica-

tor

High pressure filter

replacement of filter cartridge

Pump distribution gear

oil level check

Pump distribution gear

topping up the oil

Pump distribution gear

oil change

Hydraulic hoses

observation

Hydraulic hoses

Replace the hoses

Maintenance

Maintenance during run-in period

F 6.0 2

1.2

Points of maintenance

Hydraulic oil tank (1)

- Oil level check on dipstick (A).

In case of retracted cylinders the oil level

shall be at the upper mark.

For filling in the oil:

- Remove cap (B).

- Fill in oil through the filling port until the

required filling level is achieved on the

dipstick (A).

- Return cap (B).

Regularly clean the vent port of the oil

tank from dust and pollution. Clean the

surfaces of the oil cooler.

Use only the recommended hydraulic

oils

- see section „Recommended hy-

draulic oils“.

For changing the oil:

- To drain the hydraulic oil unscrew the

drain plug (C) at the bottom of the

tank.

- Collect the oil in a bin using a funnel.

- After drainage screw back the plug

with a new seal ring.

Change the oil when the engine is at op-

erating temperature.

When changing the hydraulic oil also

change the filter.

Hytank_dip.wmf/Hydtank_bot.bmp

F 6.0 3

Suction/return flow hydraulic filter (2)

Change the filter by the intervals speci-

fied or when the maintenance indicator

(A) at a hydraulic oil temperature of 80°C

comes to the red mark.

The temperature of the hydraulic oil can

be read on the hydraulic temperature in-

dicator (O) at the operating position.

When changing the hydraulic oil also

change the filter.

- Remove the lid fastening screws (B)

and remove the lid.

- Disassemble the withdrawn unit into

the following parts:

- lid (C)

- separating plate (D)

- filter (E)

- dirt collection cage (F)

- Clean the filter case, the lid, the sepa-

rating plate and the dirt collection

cage.

- Check and replace the O-rings (G)

when required.

- Wet the seal surfaces and the O-ring

with clean fuel.

Hydtank_V2.eps/Montage2.eps/Hydtank_V2a.eps

F 6.0 4

Venting the filter:

- Fill the open filter case with hydraulic oil to about 2 cm below the upper rim.

- Should the oil level drop, top up with oil.

A The slow sinking of the oil level by about 1 cm/min is normal!

- When the oil level remains steady, mount the assembled unit with the new filter car-

tridge, carefully into the housing and tighten the locking screws of the lid (B).

- Open the vent screw (H).

- Mount a transparent hose (l) on the vent screw and lead it into an appropriate con-

tainer.

- Start the traction engine at idling speed.

- Shut-off the bleeding screw (H) as soon as the oil discharged through the hose is

clean and free of bubbles of air.

A The process from the mounting of the filter lid until starting the engine shall take place

within 3 min or else the oil level drops too much in the filter case.

m Check the seal after changing the filter.

F 6.0 5

High pressure filter (3)

Replace the filter cartridge when the

maintenance indicator (A) turns red.

- Unscrew filter house (B).

- Remove the filter cartridge

- Clean the filter house.

- Insert the new filter cartidge.

- Replace the seal ring of the filter hous-

ing.

- Turn on the filter housing by hand and

tighten it using a wrench.

- Start the trial operation and check the

tightness of the filter.

A Replace the seal ring whenever the filter

cartridge is replaced.

A After the replacement of the filter car-

tridge the red signal of the maintenance

indicator

(A) automatically reverts to

green.

Hochdr.bmp

F 6.0 6

Pump distribution gear (4)

- Oil level checking on the viewing

glass (A) (at the side of the distribution

box).

A The oil level must be up to the center of

the viewing glass.

For filling in the oil:

- Unscrew the filling in screw plug (B).

- Fill in oil through the filling port until the

required filling level is achieved on the

viewing glass (A).

- Return filling screw plug (B).

Take care of cleanliness!

Oil change:

Change the oil when the engine is at op-

erating temperature.

- Remove the cover cap of the oil drain

port (C) and screw on the hose provid-

ed as an accessory.

- Place the end of the hose in a dish to

catch the oil.

- Open the shutoff valve with a spanner

and let the oil fully drain.

- Shut off the valve, remove the hose

and return the cover cap.

- Fill in the oil of specified quality

through the filling port on the distribu-

tion box (B) until the oil level rises to

the center of the viewing glass (A).

PVG2.wmf/PVG_Glas.wmf/F0112_A1.bmp

F 6.0 7

Hydraulic hoses (5)

- Check the condition of the hydraulic

hoses specifically.

- Immediately replace the injured hos-

es.

f The aged hoses may become porous

and burst! Risk of accident!

A The numbers stamped in the joints of the

hoses state the date of manufacture (A)

and the maximum pressure (B) allowed

for that hose.

m Do not fit hoses, which were in storage

for a long time and check the permitted

pressure rating.

DHH 09/00 225BAR

PVG2.wmf

F 6.0 8

1.1

Maintenance intervals

Interval

Points of maintenance

Remark

- Chain tightness

Inspection

- Chain tightness

setting

- Planetary gear

oil level check

- Planetary gear

topping up the oil

- Planetary gear

oil change

Maintenance

Maintenance during run-in period

F 7.1 2

1.2

Points of maintenance

Track tightness (1)

Slack tracks may slip out of the guides of

the rolls, drive and guide wheels and in-

tensive wear may take place.

Too tight tracks add to the wear of guide wheels and drive bearings, the pins and

bushes of the tracks as well.

Track tension: checking / adjusting:

- Track tightness can be adjusted with

grease press. The filling ports are lo-

cated on the LH and RH sides of the

running gear.

- Run paver drive unit onto a suitable

piece of angled timber (C) or onto a

similar object.

- To relieve strain on the track, reverse

a short distance, ensuring that the ve-

hicle remains on the angled timber.

LW_DYN2.bmp

The tack is correctly tensioned once the

slack (F) between centre roller and track

is 30-40 mm.

If a different level of slack is detected

during the measurement process, pro-

ceed as follows:

- Drive the vehicle forwards slightly, to

relieve strain on the upper track sec-

tion.

- Remove the screws (A).

Spann_LWDyn.bmp

- Remove cap (B).

- Screw the head module of the flat grease nipple (toolbox) on the grease press.

- Fill the track tensioner with grease, then remove the grease gun.

- Next, drive the vehicle forwards and backwards a few times.

- Check the track tension once again, as described above.

Repeat this procedure on both drive units!

- Remount the lid (B).

F 7.1 3

Planetary gear (2)

- For checking the oil level unscrew the

inspection 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 filling plug (A).

- Fill oil of the correct specification

through the filling hole (A) until the oil

level reaches the lower edge of the fill-

ing hole (A).

- Replace the cap (A).

Oil change:

Change the oil when the engine is at op-

erating temperature.

Make sure that no pollution or foreign

matter gets into the drive.

Gear.bmp

- Turn the drive so that the „oil max“

mark stands horizontally and the drain

screw plug (B) is at the bottom.

- Unscrew the drain plug (B) and the filling plug (A) and drain the oil.

- Check and replace the seals of both screw plugs.

- Return plug (B).

- Fill in new oil through the filling port until the „oil max“ mark is achieved.

- Drive in filling plug (A).

F 7.1 4

Interval

Points of maintenance

Remark

Also see

Generator

the opera-

Checking of operation of the insu-

tion manu-

lation monitoring of electric equip-

al of the

ment

screed

Generator

Visual checking for pollution or

damage

(o)

Check the cooling air openings

for pollution or clogging, clean as

required.

Generator

Check the ball bearings "by lis-

(o)

tening" and replace them as re-

quired.

Generator

(o)

Replacement of ball bearings

Generator

Check the drive belts (o) for inju-

(o)

ry and replace them as required.

(o)

Generator

Only on

Drive belts (o) - check tightness

version with

and adjust as required.

V-belt!

Generator

(o)

Replacement of drive belts (o)

Maintenance

Maintenance during run-in period

F 8.1 3

1.2

Points of maintenance

Batteries (1)

Maintenance of storage batteries

The batteries are filled with the appropri-

ate volume of electrolyte in the factory.

The electrolyte level shall be up to the

top mark. Top up with ion exchanged

water only, when required!

The shoes shall be free of oxyde and

coated with special battery protection

grease.

m When removing the batteries always

separate the minus pole first and avoid

short circuit between the battery poles.

Tankhood_LH.eps

F 8.1 5

Generator (2)

Checking of operation of the insulation monitoring

Check insulation daily with operating

machine and switched on connection

sockets.

- Turn on the electrical equipment with

switch (1), control light (2) comes on.

- Press testing button (3) and the in-

scription "Isolationsfehler - Insulation

Fault" shall come on.

- Depress the button clear (4) and the

insulation fault inscription will go dark.

If the test is completed successfully,

work can proceed with the electrical sys-

tem and external consumers can be

used.

If the "Insulation Fault" control light indi-

cates a fault already before pressing the

control button, then work cannot pro-

ceed with the electrical system and the

external consumers. In case of insula-

Schalt_230V.wmf/230V.wmf

tion fault the connection sockets are au-

tomatically turned off.

Work with the electric system cannot proceed if the simulation does not indicate a fail-

ure.

In case of failures, the electric equipment needs to be tested and repaired by an elec-

trician. With these devices and the equipment work can be resumed only after such

test and repair.

Danger from electric voltage

Failure to comply with the safety precautions and safety regulations can result

in electrical shock injuries from the electrical system.

Danger to life!

All maintenance and repair work on the electrical system must always be car-

ried out by an electrician!

F 8.1 6

Drive belts (V-belt)

Checking belt tension

The tightness of each belt shall be in-

spected with a tightness checking instru-

ment.

Specified tension:

- in case of first assembly: 550 N

- after run-in period /

maintenance interval: 400N

Riemensp.tif

A Instructions for checking of tightness in

the description of the tightness measuring instrument.

A The tightness measuring instrument can be ordered according to the Article No.

532.000.45!

Adjustment of belt tightness

- Release locking screw (A) that the

bracket

(B) of the tightening roller

comes to position zero (scale (C) =

0°).

- For the adjustment of the locking de-

vice loosen or turn the appropriate nut

(D) or counter-nut (E), until the tight-

ening roller contacts the loosened up-

per belt.

- Turn the bracket of the tightening roll

(B) to adjust the correct tightness, to-

wards the upper belt (scale (C) = 15°).

- Retighten locking bolt (A).

- Retighten the previously loosened nut

(D) or (E).

Replace the pump

- Reduce the belt tightness on the ad-

justing device so that the belt can be

removed from the pulley.

- Mount the new belt and adjust tight-

ness again.

Always replace the belts in sets.

Generator_belt.wmf/Generator_spann.wmf

F 8.1 8

Drive belt (toothed belt)

Replacement of belt

- Unfasten both lock nuts (A) from the

clamping lock.

- Rotate and open clamping lock (B) un-

til belt (C) can be replaced.

A Pre-tension newly fitted belt using

clamping lock (B).

- Checking / adjusting belt tension

Riemenspann.jpg

F 8.1 9

Checking / adjusting belt tension:

The tension of the V-belt must be

checked and set after the belt has been

replaced.

- The tension of the belt can only be ad-

justed using a pre-tensioning test de-

vice.

Deflection

Specified belt tension levels:

(read from

bottom to top)

- Generator 17KVA:

- Deflection force, min: 101.4N

- Deflection force, max: 110.6N

Rubber rings

Deflection

- Belt deflection approx. 9.9mm

- Generator 20KVA:

Redirection

- Deflection force, min: 72.4N

(read from

- Deflection force, max: 79.0N

bottom to top)

- Belt deflection approx. 5.4mm

Belt deflection

Read off directly below the ring. Before you use the

- Generator 28KVA:

voltage tester again, slide the ring back down again.

- Deflection force, min: 92.2N

Riemenspann.jpg

- Deflection force, max: 100.5N

Belt deflection approx. 5.4mm

If necessary, adjust the belt tension:

- Set belt to correct tension using

clamping lock (B).

- Retighten both lock nuts (A).

Further instructions for checking of ten-

sion - see description of the belt pre-ten-

sioning test device.

A belt pre-tensioning test device can be

ordered from Dynapac as a spare part!

Item number on request.

Riemenspann.jpg

F 8.1 10

Fuses in the switching cabinet (B)

F5.5

5.1

Machine drive

5.2

Machine drive

5.3

Temperature control, electric heating

5.4

Gas heating

5.5

Connection sockets with On-Off switch buttons

5.6

Connection sockets with On-Off switch buttons

5.7

Connection sockets with On-Off switch buttons

5.8

Connection sockets with On-Off switch buttons

5.9

Starting the engine

Engine regulation

Machine drive

Spray equipment

Emulsion spray appliance

Diesel fuel pump

Flasher

Headlight (glass fibre reinforced roof)

Working floodlights (o)

Particle filter (o)

Exhaust equipment (o)

Seat heating

Windscreen wiper

7,5

Reserve

F 8.1 12

Relays in the switching cabinet (C)

Starting the engine

18.2

Retracting the screed on the right hand side

18.1

Retracting the screed on the right hand side

Power supply, terminal 15

145

Engine regulation

Complementary emergency stop

free

Re-compressor

Machine drive

Engine regulation

F 8.1 13

Fuses on the operating panel

Bedienpult_konv_Kette_635_Fuse1/Fuse1.tif/Fuse.bmp

Fuse carrier (A)

No.

Engine start, start button interlock, idling speed, re-

1.1

verse indicator

1.2

Interlocking relay, Bat 15+ relay, monitoring systems

1.3

Levelling, screed stopping

1.4

Conveyor, RH-side auger

1.5

Conveyor, LH-side auger

1.6

Tamper, vibration

Hopper, screed lift and lowering, screed retraction/ex-

1.7

tension, screed power supply, re-compression lift (o),

cabin movement (o), auger lifting/lowering (o)

1.8

Emergency stopping

7.5

Fuse carrier (B)

No.

2.1

free

2.2

Horn

2.3

Road profile

7,5

2.4

Headlights on the left/right sides

7,5

2.5

RH-side low beam headlight

2.6

LH-side low beam headlight

2.7

RH-side position light

LH-side position light, instrument panel light, instru-

2.8

ment light

F 8.1 14

DYNAPAC Paver finisher F 121 C, F 141 C Type 635. Operation & Maintenance (Order number: 4812026925) - page 6