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Dynapac Asphalt paver wheeled F80W Hatz. WORKSHOP MANUAL (2019) - page 4

WORKSHOP MANUAL

13.3

Diagnostics

13.3.1

Gas equipment tightness check

Check the gas equipment for leakage when the machine is

B

parked on a flat and solid surface and the valve (5) of the gas

bottle is open.

A

Measure the gas leak on gas components where there is a dan-

ger of a gas leak.

A gas leak can be detected by means of:

•

a gas leak detector (A)

•

gas leak detection spray (B)

•

soap water.

451610

Gas equipment tightness check procedure

Start the engine.

3

Switch on the screed gas heating.

Check the tightness of the gas equipment, e.g. with a gas leak

detector.

When checking the gas equipment, pay extra attention espe-

2

cially to any damage of hoses and potential gas leaks, and also

check:

1

•

All hoses (1)

•

All fittings (2)

•

Gas supply manifold (3)

D451137A

•

Gas supply solenoid valves (4)

4

4

C451001

•

Gas bottle shut-off valve (5)

•

Tightness of the reducing valve connection to the gas bot-

tle (6)

5

•

Pressure gauge (7)

•

Reducing valve (8)

6

•

Safety valve (9)

•

Tightness of the hose connection to the safety valve (10)

9

7

8

10

D451193B

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131

13

Screed gas heating

•

Tightness of the hose and fitting connection to the burners

(11)

Perform the gas equipment tightness test.

In case of any leak, interrupt the gas supply and have the gas

2

equipment repaired by an authorised service plant or qualified

3

personnel.

Close the gas bottle shut-off valve.

Turn off the screed gas heating.

4

Closed the gas supply.

D

D

Stop the engine.

1

D451198

Do not smoke during machine operation. There is a risk

of explosion or fire. Liquid gas 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 gas leaks and in doubt,

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 and have the gas equipment re-

paired by an authorised service plant or qualified per-

sonnel.

Follow safety regulations for handling gas bottles.

There is a risk of burns. Use protective equipment.

Have the gas equipment tightness check performed by

an authorised service plant or qualified personnel.

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WORKSHOP MANUAL

13.4

Reducing valve

Ensure that individual connections are not loosened and any

gas leak is prevented. The tightening torque on the reducing

valve cap nut must not exceed 3 - 5 Nm (2.2 - 3.7 lbft.)

If the reducing valve replacement is required, perform it

with the machine with the switched off battery discon-

necter and with the closed gas bottle valve.

D451630

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 replacement is required, perform it with

the machine with the switched off battery disconnecter

and with the closed gas bottle valve.

13.6

Gas manifold

13.6.1

Gas manifold replacement

Perform the replacement of the gas manifold with the machine

with the switched off battery disconnecter and with the closed

gas bottle valve.

Remove the gas hoses (4x).

D451611

D451612

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133

13

Screed gas heating

Loosen the fittings (5x).

D451613

Remove the screws (2x).

D451614

D451615

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WORKSHOP MANUAL

13.7

Screed heating burner

13.7.1

Screed heating burner replacement

Perform the replacement of the screed heating burner with the

machine with the switched off battery disconnecter and with

the closed gas bottle valve.

Remove the hose.

D451596

Loosen the screw and replace the burner.

Note

When reassembling, observe the correct leading of the hose

and prevent its breakage.

D451597

When reassembling, observe the correct location of the burner

lower mark.

D451599

D451600

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135

13

Screed gas heating

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.

D451596

Loosen the screw and replace the burner.

D451597

D451598

Remove the burner.

D451601

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WORKSHOP MANUAL

Clean the nozzle hole with a suitable wire.

D451602

D451603

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137

13

Screed gas heating

13.7.3

Gas flame adjustment

Open the access to the burners.

Insert the key into the ignition 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 than 15 s.

12

Use the alarm horn (12) to signal that the engine is starting.

11

Turn the key to position “II” to start the engine.

Secure the screed against free fall.

Set the maximum paving width on both sides of the machine.

451802A

Turn the key in the ignition box (11) from position “II” to position

“I”. The engine switches off.

Turn the key in the ignition box (11) from position “I” to position

“0” and disconnect the battery disconnecter.

24

Have the correct position of the gas flame adjusted.

Have the flame position adjustment performed by an author-

ised service 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 (1)

on the burner holder (2).

The distance (D) can only be adjusted within the MIN and MAX

marks. The values of MIN and MAX are marked on the burner

holder (2) by marks.

D451064G

After adjusting the burner (3), tighten the burner set screw (1)

on the burner holder (2).

Test the ignition of the burners. In case of incorrect adjustment,

repeat the gas flame adjustment procedure.

2

3

Perform gas flame adjustment when the machine is

4

parked on a flat and solid surface with the engine and

D

battery disconnecter off.

D

Have the gas flame adjustment performed by an author-

ised service plant or qualified personnel according to the

1

given procedure.

D451198

There is a risk of burns. Use protective equipment.

There is a risk of explosion.

Do not smoke during machine operation. There is a risk

of explosion or fire. Liquid gas 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.

451120

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WORKSHOP MANUAL

13.7.4

Test of burner ignition

When testing the burner ignition, check the behaviour of the

burners and the position of the gas flame.

The behaviour of the burners when ignited is correct if the burn-

ers ignite within a few seconds.

Unless the burners ignite within a few seconds, the ignition box

stops further attempts for igniting the burners and interrupts

gas supply.

12

11

Burner ignition test procedure

13

Open the access to the burners.

Insert the key into the ignition box (11) in the position “0” and

451802

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 than 15 s.

24

Use the alarm horn (12) to signal that the engine is starting.

Start the engine by turning the key to position “II”.

Secure the screed against free fall.

Set the maximum paving width on both sides of the machine.

Turn the key in the ignition box (11) from position “II” to position

“I”. The engine switches off.

Switch on the gas screed heating system 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

D451064G

screed heating system and perform a test of spark plugs, or have

spark plug maintenance performed. Have the test and mainte-

nance of spark plugs performed by an authorised service plant

or qualified personnel according to the procedure given below.

Visually check the gas flame position on all burners (1). Perform

the visual check through the burner pipe (2) and check their po-

sition with regard to the spark plug (3).

1

If the gas flame is incorrect, have the flame position adjusted.

Have the flame position adjustment performed by an author-

ised service or qualified personnel according to the procedure

given below.

Switch off the gas screed heating system by moving the switch

3

(13) to the lower position.

2

Close the access to the burners.

Set the key between position “I” and “II” and the engine glowing

D451198B

indicator lamp (24) will light up.

Do not perform engine glowing for more than 15 s.

Use the alarm horn (12) to signal that the engine is starting.

Start the engine by turning the key to position “II”.

Set the minimum paving width on both sides of the machine.

Unlock the screed and lower it to the ground.

Turn the key to the position “0” and remove the key from the

ignition box (11).

451120

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WORKSHOP MANUAL

13.8

Gas supply 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 the fitting.

D451616

D451617

Remove gas supply valves.

D451618

Remove the valve body coil core.

D451619

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13

Screed gas heating

Check that the strainer inside the valve body is not clogged.

D451620

Note

When reassembling, observe the correct placement of the valve

so that the arrow on the valve corresponds to the gas flow direc-

tion.

D451621

13.8.2

Measuring resistance of the coils of gas

supply valve electromagnets

Measure the coil resistance of approximately 18 Ω.

Note

If a different value is measured, replace the coil.

D451622

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WORKSHOP MANUAL

13.8.3

Measuring power supply of the coils of

gas supply valve electromagnets

Turn 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.

11

13

451A802

Measure the battery voltage (12 V) on the sockets of electro-

magnets Y14 and Y15 between pins 1 and 2.

If a different value is measured, check:

•

fuse F6

•

relays K6 and K10

•

wiring between the valve and the units A6, A7 and A8.

1

2

D451623

D451624

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13

Screed gas heating

13.9

Ignition units

13.9.1

Measuring resistance on the ignition

unit

Measure resistances on the ignition unit on the machine with

the switched off battery disconnecter and with the closed gas

bottle valve.

Measure the resistance on the unit with disconnected supply

cables.

Measure the resistance of approximately 53.2 Ω between pin 3

D451636

and pin of the frame.

There is an opened circuit between pin 3 and pins 1 and 2.

There is an opened circuit between the pin of the frame and

pins 2 and 3.

D451637

Measure the resistance of approximately 1.6 Ω between pin 3

and pin 4.

Note

If a different value is measured, replace the ignition unit.

D451638

Measure approximately 1.55 MΩ between the pin of the frame

and pin 4.

Note

If a different value is measured, replace the ignition unit.

D451639

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13.9.2

Voltage measurement on the cable

harness of ignition units

Measure the voltage on the cable harness of ignition units on

the machine with the closed gas bottle valve.

Remove the cover of connector X73, X74 or X75.

D451640

Turn the key in the ignition box (11) to the “I“ position.

11

451641

Measure the voltage of approximately 2.72 V 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 on connector X73,

X74 or X75 and the required pin of the central earthing point

X6.

D451642

Measure the voltage of approximately 2.72 V between pin 1 and

pin 2.

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 on connector X73,

X74 or X75 and the correct pin of the central earthing point

X6.

D451643

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13

Screed gas heating

Switch on the gas screed heating system by moving the switch

(13) to the upper position.

Measure the voltage of the battery (12 V) between the pin of the

frame and pins 2 and 3.

13

451644

13.10

High-voltage cables

Measure and replace the high-voltage cables on the machine

with the switched off battery disconnecter and with the closed

gas bottle valve.

Measure the resistance of approximately 1 kΩ.

Note

If a different value is measured, replace the high-voltage cables.

D451625

13.11

Spark plugs

13.11.1Spark plug function test

Insert the key into the ignition 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 than 15 s.

12

Use the alarm horn (12) to signal that the engine is starting.

11

Turn the key to position “II” to start the engine.

13

Secure the screed against free fall.

Set the maximum paving width on both sides of the machine.

451802

Turn the key in the ignition box (11) from position “II” to position

“I”. The engine switches off.

Close the gas bottle shut-off valve.

24

Switch on the gas screed heating system by moving the switch

(13) to the upper position.

Test the spark plugs for sparking and correct sending of the sig-

nal pulse.

Switch off the gas screed heating system by moving the switch

(13) to the lower position.

Turn the key to the “0” position.

Disconnect the battery disconnecter.

D451064G

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13.11.2Spark plug check procedure

Dismount the cable (4) of a spark plug (3).

Dismount the spark plug (3).

Check the middle electrode (5)

If the spark plug is too burned, replace the spark plug (3) for

a new one.

Measure the distance between the middle electrode (5) and

the external electrode (6). The correct distance must be 4 mm

4

(0.2 in).

In case of incorrect distance, adjust the distance between the

3

middle electrode (5) and the external electrode (6) by slightly

bending the external electrode (6).

D451199A

Screw in the spark plug (3).

Mount the cable of the spark plug (4).

Perform the spark plug test again according to the previous pro-

cedure.

Unless the burners start within a few seconds, repeat the whole

procedure.

4 mm (0,2 in)

5

Perform maintenance of spark plugs when the machine

3

6

is parked on a flat and solid surface with the engine and

battery disconnecter off.

Have the test and maintenance of spark plugs performed

D451152

by an authorised service plant or qualified personnel ac-

cording to the given procedure.

There is a risk of burns. Use protective equipment.

F80W

147

13

Screed gas heating

13.12

Temperature sensor

Measure the temperature sensor on the machine with the

closed gas bottle valve.

Measure the resistance of approximately 1.1 kΩ at the tempera-

ture of 20°C on the pins of the temperature sensor.

D451645

Measure the voltage of approximately 3.32 V on the pins of the

temperature sensor socket.

Note

If a different voltage value is measured, check the wiring be-

tween the control unit A2 and the sensor S18.

In case of a short circuit or interruption of the cables, the error

message F70 is displayed.

D451646

148

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14

Belt conveyors and augers

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.

D421524

Remove the cover of the drive for belt conveyors and augers.

D421525

Remove the hydraulic hoses.

Avoid the oil soaking into the ground.

D421526

D421527

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D421528

Remove the tension screw.

D421529

Remove the screw for fastening the tension mechanism of the

auger chain.

D421530

D421531

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151

14

Belt conveyors and augers

Remove fastening screws of the hydraulic motor (2x).

D421532

Take out the hydraulic motor for driving the belt conveyor and

auger.

Note

When reassembling the hydraulic motor of augers and belt con-

veyors, proceed in the reverse order.

D421533

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14.2

Dismounting the belt conveyor chain

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 chain and the cylinder is 0 mm at the latest.

D451534

Remove the rear wheels on the left side of the machine.

D451517

D451518

D451519

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153

14

Belt conveyors and augers

Remove the drive chain of the belt conveyor.

•

Remove the screws of the hydraulic motor (2x).

D451539

•

Loosen the hydraulic motor screws (2x). Pull the hydraulic

motor slightly out towards you.

D451540

•

Cut the binding strap of the hose and remove the cover of

the drive.

D451541

•

Remove the tension screw for the conveyor drive.

D451542

154

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WORKSHOP MANUAL

•

Remove the screw.

D451543

•

Remove the screw and the washer.

D451544

•

Remove the lock ring.

D451545

•

Remove the gear wheels.

D451546

F80W

155

14

Belt conveyors and augers

Loosen the tension screws of the belt conveyor on the left and

right side of the machine.

D451535

By moving the belt conveyor find and dismount chain coupling

links (2x).

D451536

Take the chain out of the machine.

D451537

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WORKSHOP MANUAL

14.3

Mounting the belt conveyor chain

Mount the belt conveyor chain to the machine with the switched

off battery disconnecter and with the 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 chain.

Note

Ensure that the conveyor chain is installed with the contact sur-

face to the chain guide plate.

DD451038

451567

D451568

Ensure that the chain is at the same distance from the machine

frame on both sides.

D451569

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157

14

Belt conveyors and augers

Tighten the tension screws on the left and right side of the ma-

chine. Test the correct running of the chain by 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 according to Chapter 14.5.

D451535

Mount the drive chain of the belt conveyor.

•

Mount the gear wheels with the chain for driving the belt

conveyor.

D451546

•

Mount the lock ring.

D451545

•

Mount the screw and the washer.

D451544

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WORKSHOP MANUAL

•

Mount the screw.

D451543

Remove the tension screw for the belt conveyor drive and mo-

tor cover.

•

Tighten the hydraulic motor screws (2x).

D451540

•

Mount the screws of the hydraulic motor (2x).

D451539

Note

Secure the screws of the hydraulic motor

(4x) with the

LOXEAL 83.54 adhesive.

D451A522

F80W

159

14

Belt conveyors and augers

•

Mount the rear wheels on the left and right side of the ma-

chine.

D451519

D451518

D451517

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WORKSHOP MANUAL

14.4

Setting the belt conveyor chain sag

Calculate the sag of the conveyor chain by measuring the dis-

tance between the ground and the left conveyor chain (1) or the

right conveyor chain (2), always in the central part of the chain.

The chain is correctly tensioned when there is an approx.

30 - 40 mm sag (1.2 - 1.6 in) in the middle.

Chain sag calculation procedure:

1

2

•

The procedure is identical for the left (1) and right (2) con-

veyor chain.

•

Measuring the distance between the ground and the chain

in the middle part of the chain (1).

451135

•

Press the chain upwards in the middle part 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 an approx.

30 - 40 mm sag (1.2 - 1.6 in) in the middle.

30-40 mm (1,2-1,6 in)

1

451200

Chain tensioning procedure:

•

The procedure is identical for the left (1) and right (2) con-

veyor chain.

•

Loosen the lock nut (4).

•

Tension the chain using the adjusting nut (5).

•

Calculate the sag of the chain (1) by deducting the two

measured values according to the procedure above.

•

If the calculated sag is in the range of 30 - 40 mm (1.2 - 1.6 in),

tighten the lock nut (4).

•

Tension the chain equally on both sides of the machine.

4

5

Note

451134

In case of too high chain tension, loosen the lock nut (4) and the

adjusting nut (5).

Calculate the sag of the chain (1) by deducting the two meas-

ured values according to the procedure above.

F80W

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WORKSHOP MANUAL

14.5

Dismounting the belt conveyor 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 side of the ma-

chine.

Remove the screws.

D451517

D451518

D451519

Remove the screws of the hydraulic motor (2x).

D451539

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163

14

Belt conveyors and augers

Loosen the hydraulic motor screws (2x). Pull the hydraulic motor

slightly out towards you.

D451540

Cut the binding strap of the hose.

Remove the drive cover.

D451541

Remove the tension screw for the conveyor drive.

D451542

Remove the screw.

D451543

164

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WORKSHOP MANUAL

Remove the screw and the washer.

D451544

Remove the lock ring.

D451545

Remove the gear wheels with the chain for driving the belt con-

veyor.

D451546

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165

14

Belt conveyors and augers

14.6

Dismounting 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 machine.

Remove the screws.

D451517

DD451061

DD451060

Set the lever for material outlet to the lower position.

D421524

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WORKSHOP MANUAL

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.

D421525

Remove the lock screws.

D451548

Remove the augers.

Remove the lock screw.

D451549

Remove the lock screws.

D451550

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167

14

Belt conveyors and augers

Remove the bearing housing on the left and right side.

D451551

Take the shaft out.

D451552

Pull out the auger chain.

Note

Proceed in the reverse order when reassembling the auger

chain.

D451553

168

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WORKSHOP MANUAL

14.7

Replacement of the drive 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 valve.

Disconnect the connector X43.

D451554

Remove the adjusting screw.

D451555

Take out the switch.

D451556

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