Dynapac Asphalt paver wheeled F80W Hatz. WORKSHOP MANUAL (2019)

Engine

7.2

Technical data of the manufacturer

General technical data

Engine type

1B40T

Working principle

Air-cooled four-stroke diesel engine

Combustion process

Direct injection

Number of cylinders

Bore/stroke

88/76 mm (3.46/2.99 in)

Total volume of cylinders

462 cm³

Tank capacity

5 l (1.32 gal US)

Engine oil capacity without an oil collector

1.5 l (0.4 gal US)*

Engine oil capacity with an oil collector

3.2 l (0.85 gal US)*

Difference between the minimum and maximum marking

0.8 l (0.21 gal US)*

without an oil collector

Difference between the minimum and maximum marking with

2.2 l (0.58 gal US)*

an oil collector

Engine oil consumption

Max. 1% of fuel consumption, referred to the full load

Oil pressure at 100°C

Approximately 2.5 bar at 3000 rpm

Direction of rotation when looking at the flywheel

Left

Valve clearance at 10-30°C

0.10 mm (0.0039 in)

Maximum allowed inclination during operation in the given

Flywheel side 25°C **

direction

Other directions 35°C **

Weight (including the fuel tank, air filter, damper and electric

Approximately 55 kg (121.25 lb)

start)

Battery capacity

Min. 12 V - 36/55 Ah

Max. 24 V - 24/44 Ah

* These specifications are approximate values. The maximum marked value on the dipstick is always decisive.

** Exceeding these limit values will cause damage to the engine.

F80W

WORKSHOP MANUAL

7.3

Engine diagnostics

All measured values are measured using a multimeter.

D451405

7.3.1

Measuring glow plug resistance

Remove wire no. 6.

D451406

The measured resistance is approximately 0.9 Ω.

Note

In case of the measured value - open circuit, replace the glow

plug.

D451407

7.3.2

Measuring glow plug power supply

Measure voltage of approximately 12 V between wire no. 6 and

the engine frame with the engine pre-heating switched on.

D451408

F80W

Engine

7.3.3

Measuring temperature sensor

Remove wire no. 5.

D451409

Measure the resistance between the engine frame and the con-

necting screw.

D451410

The switch is disconnected (the disconnected circuit). The

switch is connected at the temperature of 220°C and the resist-

ance is approximately 1.8 Ω.

D451411

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-

mately 2.7 V.

Note

The measured value must be approximately 1.8 Ω at the engine

temperature of 220°C. If disconnected circuit is measured, re-

place the switch.

To verify the function

When the engine is overheated, attach wire no. 5 to the engine

frame and the fan must start up.

D451412

F80W

WORKSHOP MANUAL

7.3.4

Measuring lubricating oil pressure

switch

Remove wire no. 4.

D451413

Measure the resistance between the frame and the lubricating

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.

D451414

Before measuring voltage make sure that the key in ignition is

in the “I” position.

The voltage between wire no. 4 and the engine frame with the

engine started is approximately 2.7 V.

D451412

F80W

Engine

7.3.5

Measuring extinguishing valve

Before measuring voltage make sure that the key in ignition is

in the “I” position.

Remove wire no. 7.

D451415

Measure the resistance between the wire at the output from the

coil and the machine frame.

The measured resistance is approximately 10.5 Ω.

D451416

Measure the voltage of the extinguishing coil between wire no.

7 and the engine frame.

The voltage of the extinguishing valve is approximately 7.3 V.

D451417

F80W

Engine

7.4

Dismounting 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.

D451421

Disconnect the wire and connectors of the charging controller.

D451422

Remove the screws.

D451423

F80W

WORKSHOP MANUAL

7.5

Mounting the charging controller

Mount the charging controller to the machine with the switched

off battery disconnecter and with the closed gas bottle valve.

Fasten the controller.

D451423

Connect the wire and connectors of the charging controller.

D451425

Connect the wire and connectors and fasten them with a bind-

ing strap.

D451424

F80W

Engine

7.6

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.

D451426

Disconnect the connectors.

D451427

Dismount the wire to the starter.

D451428

Dismount the engine earthing wire.

D451429

F80W

WORKSHOP MANUAL

7.7

Mounting 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.

D451442

Mount the screws of the engine holder and tighten them.

D451438

D451439

Fit the coupling onto the pump and insert the pump to the en-

gine.

D451436

F80W

WORKSHOP MANUAL

Mount the engine speed cable.

D451474

Mount the locking screw of the engine speed cable.

Note

Make sure that the mark of the cable is at the same place.

D451431

Mount the engine earthing wire.

D451429

Mount the wire to the starter.

D451428

F80W

Engine

7.8

Engine speed adjustment

Measure the engine speed using a revolution counter.

Idle engine speed

Start the engine and set the engine speed adjusting controller

to idle speed.

Loosen the lock nut.

D451445

Turn the screw until it reaches 1200 RPM.

D451447

D451419

Tighten the lock nut.

D451445

F80W

WORKSHOP MANUAL

8.2

Technical data of the manufacturer

•

Open-centre power steering

•

Volume of 50 cm³/revolution.

•

Maximum pressure of 50 Bar.

D451063

8.3

Diagnostics

Measuring the steering pressure

•

Measure the pressure 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 the refilling pressure in the steering of approximately

22 Bar.

The maximum pressure in steering limit positions is approxi-

mately 50 Bar.

D451451

Note

In case a different value is measured, contact your dealer or DY-

NAPAC Technical Support.

F80W

Steering

8.4

Replacement of the gear pump

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 soaking into the ground.

D451452

Remove the screws.

Replace the pump with a new one.

D451453

D451454

F80W

Steering

8.5

Dismounting the steering linear

hydraulic motor

Dismount the steering linear hydraulic motor from the machine

with the switched off battery disconnecter and with the closed

gas bottle valve.

Turn the 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.

D451458

Remove the screw of the steering hydraulic motor.

D451455

Remove the screws of hoses of the steering hydraulic motor.

Note

Place a container underneath the hoses of the steering hydraulic

motor to trap the oil.

Avoid the oil soaking into the ground.

D451456

Remove the screw of the steering hydraulic motor.

D451457

F80W

Steering

8.6

Mounting the steering linear hydraulic

motor

Mount the steering linear hydraulic motor to the machine with

the switched off battery disconnecter and with the closed gas

bottle valve.

Insert the steering hydraulic motor and mount the screw.

D451460

Mount the screws of hoses of the steering hydraulic motor.

D451456

Mount the screw of the steering hydraulic motor and glue it with the

LOXEAL 83∙54 adhesive.

D451455

Mount the cable on the steering hydraulic motor.

Note

Make sure that the mark of the cable is at the same place.

During the back assembly it is necessary to adjust the steering

indicator to the central position by loosening or tightening the

cable on the steering hydraulic motor.

D451458

F80W

WORKSHOP MANUAL

8.7

Dismounting 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.

D451461

Remove the screw.

D451462

Take out the steering wheel and remove the screws.

D451463

Cut off the binding straps of hydraulic hoses.

D451464

F80W

Steering

Take out the steering hydraulic unit.

Remove the hydraulic hoses on the steering unit.

Avoid the oil soaking into the ground.

Note

When mounting the steering hydraulic unit back proceed in the

D451465

reverse order and take care of the correct connection of the hy-

draulic hoses.

0018

0034

- Hose 0028 at position T

- Hose 0018 at position P

– Hose 0034 at position L

- Hose 0033 at position R

0028

0033

421523

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 surface, the engine and the battery discon-

necter are 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 drain plug (3).

Remove the drain plug (3) from the hydraulic tank.

Drain the oil into the prepared container.

Mount the drain plug (3) onto the hydraulic tank and tighten.

D451255C

Avoid the oil soaking into the ground.

D451A466

F80W

WORKSHOP MANUAL

Fill in the hydraulic tank:

MAX

•

Fill in new oil to the hydraulic tank through the hole (1).

•

The prescribed oil volume is 20 l (5.3 gal US).

MIN

•

Check the oil level on the oil gauge (2).

•

The hydraulic oil level must be between the MIN and MAX

marks.

D451256B

8.10

Adjustment of the front wheel turning

angle indicator

Adjust the indicator by tightening or loosening the adjusting

screw.

D451471

Note

If the tightening or loosening of the adjusting screw is insuf-

ficient, change the position of the cable on the steering linear

hydraulic motor.

D451458

F80W

Travel

9.1

Description of basic elements

Service pump

Measuring point for pressure measurement

D451486

Measuring point for pressure measurement for forward travel

DD451046

Measuring point for pressure measurement for reverse travel

DD451047

Coil of the valve electromagnet for forward travel Y12

Coil of the valve electromagnet for forward travel Y13

DD451048

F80W

WORKSHOP MANUAL

9.2

Diagnostics

9.2.1

Measuring the brake switch

Brake enabled = the switch disconnected.

•

Brake pressure 0 Bar.

Brake disabled = the switch connected = released brake of the

machine

•

Pressure of 22 Bar.

Measuring brake switch pressure

DD451031

•

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 the engine speed adjusting controller

to the maximum speed and put the machine in motion.

DD451032

•

Measure the brake release pressure of approximately 22 Bar.

Note

In case a different value is measured, contact your dealer or DY-

NAPAC Technical Support.

DD451033

F80W

Dynapac Asphalt paver wheeled F80W Hatz. WORKSHOP MANUAL (2019) - page 2