Page 1 WORKSHOP MANUAL Asphalt paver wheeled F80W Hatz 4812077915...
Page 3 F80W Asphalt paver, wheeled Hatz Workshop manual Edition 10/2021 EN From Serial No. 3016546...
Page 5 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. If you identify any differences between the machine operated by you and the information contained in this publication, contact your local dealer.
Page 6: Table Of Contents
Contents Contents ��2 INTRODUCTION ��7 SAFETY MEASURES AND INSTRUCTIONS ��11 Safety rules ..........................................12 Environmental and hygiene principles ..............................15 Fire prevention ........................................16 MACHINE DESCRIPTION ��17 SPECIFICATION MANUAL ��23 Basic data ..........................................24 Dimensional drawing of the machine ...............................26 Technical data ........................................28 Machine gradeability and lateral static stability of the machine .....................30 SPECIFICATION OF OPERATING FLUIDS ��33 Engine oil ..........................................34 Fuel ............................................35...
Page 7 WORKSHOP MANUAL STEERING ��63 Description of basic elements ..................................64 Technical data of the manufacturer................................65 Diagnostics .........................................65 Replacement of the gear pump ...................................66 Dismounting the steering linear hydraulic motor ..........................68 Mounting the steering linear hydraulic motor ............................70 Dismounting the steering unit ..................................71 Removal of the hydraulic tank ..................................72 Mounting the hydraulic tank ..................................74 8.10...
Page 8 Contents SCREED ��115 12.1 Dismounting the screed lifting cylinder ..............................116 12.2 Replacement of linear hydraulic motors for screed extension ...................... 118 12.3 Basic setting of the screed ..................................120 12.4 Replacement of the friction plates ................................123 12.4.1 Front frame ........................................124 12.4.2 Rear frames ........................................
Page 9 WORKSHOP MANUAL WIRING ��183 15.1 Description of basic components ................................184 15.1.2 Central earthing points X6 and x7 ................................185 15.2 Diagnostics ........................................186 15.2.1 List of error codes displayed on the display ............................186 15.2.2 Fuse box ..........................................189 15.2.3 Diagnostics socket ......................................
Page 10 F80W...
Page 11: Introduction
WORKSHOP MANUAL Introduction F80W...
Page 12 Labelling of machine subassemblies in this manual corresponds to the spare parts catalogue. In order to ensure smooth operation of the DYNAPAC compaction equipment, use only original spare parts supplied by DY- NAPAC for repairs� The manufacturer constantly improves its products on 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.
Page 13 WORKSHOP MANUAL SAFETY NOTICES AND SIGNS: The notice warns of a serious risk of personal injury 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 terms right, left, front and rear indicate sides of the machine moving forward�...
Page 14 F80W...
Page 15: Safety Measures And Instructions
WORKSHOP MANUAL Safety measures and instructions F80W...
Page 16: Safety Rules
Safety measures and instructions 2�1 Safety rules These safety rules must be followed by all persons involved in machine repairs! • Repairs of this machine may be carried out only by qualified, professionally trained and experienced workers or by the Service personnel of our dealers.
Page 17 WORKSHOP MANUAL Safety measures for work on hydraulic circuits • Before disassembly, make sure the hydraulic circuits are depressurized. Hydraulic oil leaking under pressure may damage your skin and cause serious injury. • Before disassembly, mark the parts, hoses and pipes. •...
Page 18 Safety measures and instructions Safety measures for work on the electrical system • Disconnect the battery when repairing the charging circuit to prevent accidental short circuits. • Before removal, disconnect the cable from the negative terminal (-) and then from the positive terminal (+). •...
Page 19: Environmental And Hygiene Principles
WORKSHOP MANUAL 2�2 Environmental and hygiene principles When repairing the machines, observe general principles of health and environmental protection as well as laws and regulations re- lated to this issue and being in force within the territory where the machine is used. Hygienic principles •...
Page 20: Fire Prevention
Safety measures and instructions 2�3 Fire prevention • The oil change area must be located so that it does not interfere with any explosion or fire hazard area. • It must be identified by the tables and marks with “No smoking” signs and signs prohibiting the use of naked fire. •...
Page 21: Machine Description
WORKSHOP MANUAL Machine description F80W...
Page 22 Machine description D452051 F80W...
Page 23 WORKSHOP MANUAL Legend: 1. Augers 2. Screed tow arm 3. Travel wheels 4. Machine frame 5. Belt conveyors 6. Screed lock 7. Screed 8. Tilting platform 9. Engine 10. Paving thickness indicator 11. Hopper 12. Exhaust 13. Main dashboard 14. Steering wheel 15.
Page 24 Machine description 451033B D451032C F80W...
Page 25 WORKSHOP MANUAL 37. Roadway profile bottom plates 38. Crown adjustment 39. Screed end gate 40. Screed vibrators 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 Foot switch 49.
Page 26 F80W...
Page 27: Specification Manual
WORKSHOP MANUAL Specification manual F80W...
Page 28: Basic Data
Specification manual 4�1 Basic data Machine type Machine description ....................... The F80W wheeled asphalt paver is equipped with a screed with Serial number of the machine gas heating. The basic paving width is from 800 mm (31.5 in) to 1,300 mm (51.2 in). The machine is characterised with good manoeuvrability, good .......................
Page 29 WORKSHOP MANUAL Nameplate. Serial number of the machine . D451023 Serial number of the engine. D451024 Nameplate of the screed. Serial number of the screed. D451025A F80W...
Page 30: Dimensional Drawing Of The Machine
Specification manual 4�2 Dimensional drawing of the machine D451170A F80W...
Page 31 WORKSHOP MANUAL 1280 2070 2680 1598 2865 2526 50.4 81.5 105.5 62.9 112.8 99.4 2550 1150 1699 100.4 30.1 25.2 31.5 45.3 66.9 F80W...
Page 32: Technical Data
Specification manual 4�3 Technical data F80W EU Stage V, U�S� EPA Tier 4f Weight Operating weight of the machine (including: bar extension, double driving wheels, vibration) kg (lb) 1265 (2790) Transport weight kg (lb) 1190 (2620) Driving characteristics Number of speeds Working speed km/h (MPH) Transport speed...
Page 33 WORKSHOP MANUAL F80W EU Stage V, U�S� EPA Tier 4f Fluid capacities Fuel l (gal US) 5 (1,3) Engine (oil filling) l (gal US) 1,9 (0,5) Hydraulic system l (gal US) 20 (5,3) Reduction gearboxes l (gal US) Pumps coupling l (gal US) Lubricating substances kg/lb...
Page 34: Machine Gradeability And Lateral Static Stability Of The Machine
Specification manual 4�4 Machine gradeability and lateral static stability of the machine Machine gradeability with an empty hopper (screed in the lower position). α = 7° (12%) D451171 Machine gradeability with a full hopper (screed in the lower po- sition). α = 11° (19%) D451172 Machine descent with an empty hopper (screed in the lower position).
Page 35 WORKSHOP MANUAL Lateral static stability with an empty and full hopper. α = 12° (21%) D451175 F80W...
Page 36 F80W...
Page 37: Specification Of Operating Fluids
WORKSHOP MANUAL Specification of operating fluids F80W...
Page 38: Engine Oil
Specification of operating fluids 5�1 Engine oil Viscosity diagram 2412 Engine oil has been specified as per its performance classifica- °F °C tion and viscosity classification. Performance classification according to API (AMERICAN PETROLEUM INSTITUTE) ACEA (ASSOTIATION DES CONSTRUCTEUERS EUROPPÉENS DE AUTOMOBILE) Viscosity classification To determine the SAE (Society of Automotive Engineers) viscos-...
Page 39: Fuel
WORKSHOP MANUAL 5�2 Fuel 5�4 Anti-adherent solution AMN411 Diesel oil is used as fuel for the engine: The anti-adhesive liquid is a non-adhesive additive. • EN 590 It serves for cleaning the hopper, conveyor, augers and parts of the machine which are in contact with the paved asphalt mate- •...
Page 40: Liquid Gas
Specification of operating fluids 5�5 Liquid gas 5�6 Lubricating grease 0787 The machine is equipped with a gas heating system that uses To lubricate the machine you must use a plastic grease contain- liquid gas as fuel. ing lithium according to: • Propane-butane (LPG) ISO 6743/9 CCEB 2 DIN 51 502 KP2K-30...
Page 41: Fluids
WORKSHOP MANUAL 5�7 Fluids Filling quantity Part Fluid type Brand l (gal US) Engine Engine oil according to Chapter 5.1. 1.8 l (0.48 gal US) 2412 Fuel tank Fuel according to Chapter 5.2. 5 l (1.3 gal US) Hydraulic system Hydraulic oil according to Chapter 5.3.
Page 42 F80W...
Page 43: Lubrication And Maintenance Chart
WORKSHOP MANUAL Lubrication and maintenance chart F80W...
Page 44 Lubrication and maintenance chart Every 10 hours at the beginning of work (daily) 3.6.1 Fuel level check 3.6.2 Engine oil level check 3.6.3 Hydraulic tank oil level check 3.6.4 Driver's stand cleaning 3.6.5 Cleaning the hopper, outlets and conveyor 3.6.6 Cleaning the augers 3.6.7 Test of burner ignition, flame position adjustment and spark plug maintenance 3.6.8...
Page 45 WORKSHOP MANUAL Every 500 hours of operation, but at least once a year 3.6.25 Replacement of fuel filters 3.6.26 Air filter replacement 3.6.27 Front and rear wheel condition check After 500 hours of operation 3.6.29 Hydraulic oil and hydraulic oil filter replacement** Every 1000 hours 3.6.28 Engine oil filter cleaning...
Page 46 Lubrication and maintenance chart LUBRICATION AND SERVICE PLAN INSPECTION LUBRICATION REPLACEMENT 1000 SAE 15W-40 API CK-4 / CJ-4 Engine oil: ISO VG 46 ISO 6743/HV Hydraulic oil: Lubricating grease: ISO 6743/9 CCEB 2 Specification according to the coun- Anti-adherent solution: try of machine operation D452054 F80W...
Page 47: Engine
WORKSHOP MANUAL Engine F80W...
Page 48: Description Of Engine Basic Elements
Engine 7�1 Description of engine basic elements Glow plug Temperature sensor Lubricating oil pressure switch 451400 One-way valve Oil pressure switch Electromagnetic fuel filter D452042 Air filter Oil dipstick Oil filter 10 Speed sensor 11 Fuel filter 12 Fuel feed pump D452043 13 Condensate drain 14 Charging controller...
Page 49 WORKSHOP MANUAL 16 Fuel tank D452045 17 ECU unit D452046 F80W...
Page 50: Technical Data Of The Manufacturer
Engine 7�2 Technical data of the manufacturer General technical data Engine type 1B50E 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 cm 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...
Page 51: Engine Diagnostics
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 0.7 Ω. Note In case of the measured value – open circuit, replace the glow plug.
Page 52: Measuring Temperature Sensor
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.
Page 53: Measuring Lubricating Oil Pressure Switch
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.
Page 54: Measuring Engine Speed
Engine 7�3�5 Measuring engine speed Remove the cover. D451418 Measure the engine speed using a revolution counter. Measure idling of approximately 1200 RPM. D451419 Measure maximum speed of approximately 2600 RPM. D451420 F80W...
Page 55: Dismounting The Charging Controller
WORKSHOP MANUAL 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. D452001 Disconnect the wire and connectors of the charging controller. D452002 Remove the screws.
Page 56: Mounting The Charging Controller
Engine 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. D452003 Connect the wire and connectors of the charging controller. Connect the wire and connectors and fasten them with a bind- ing strap.
Page 57: Dismounting The Engine
WORKSHOP MANUAL 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. D452005 Dismount the wire to the starter. D451428 Dismount the engine earthing wire.
Page 58 Engine Remove the holder. D452007 Remove the exhaust clip and holder. D452008 D452009 F80W...
Page 59 WORKSHOP MANUAL Remove the lower hose clip. D452010 Remove pump bolts. D451435 Move the pump aside and remove the coupling. D451436 D451437 F80W...
Page 60 Engine Remove the screws of the engine holder (4x). D452011 D452012 Remove the air filter cover. D451440 F80W...
Page 61 WORKSHOP MANUAL Remove the top engine cover. D451651 Hang the engine in the lifting lug on the crane. D451442 D451443 F80W...
Page 62: Mounting The Engine
Engine 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. D452011 D452012 F80W...
Page 63 WORKSHOP MANUAL Fit the coupling onto the pump and insert the pump to the en- gine. D451444 D451435 Mount the screws of the pump. Remove the lifting lug. D451434 Mount the lower hose clip. D452010 F80W...
Page 64 Engine Mount the exhaust clip and holder. D452008 D452009 Mount the engine earthing wire. D452006 Mount the wire to the starter. D451428 F80W...
Page 65 WORKSHOP MANUAL Mount the holder. D452007 Connect the connectors. D452005 Mount the top engine cover. D451651 Mount the air filter cover. D451440 F80W...
Page 66 Engine Connect the battery. D451426 F80W...
Page 67: Steering
WORKSHOP MANUAL Steering F80W...
Page 68: Description Of Basic Elements
Steering 8�1 Description of basic elements Service pump Measuring point for pressure measurement D451448 Power steering DD451045 Steering hydraulic motor D451450 F80W...
Page 69: Technical Data Of The Manufacturer
WORKSHOP MANUAL 8�2 Technical data of the manufacturer • Open-centre power steering • Volume of 50 cm /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.
Page 70: Replacement Of The Gear Pump
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.
Page 71 WORKSHOP MANUAL Mount the screws and fasten the pump. D451453 D451454 Mount the suction and discharge hose. D451452 F80W...
Page 72: Dismounting The Steering Linear Hydraulic Motor
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.
Page 73 WORKSHOP MANUAL Replace the steering hydraulic motor. D451459 F80W...
Page 74: Mounting The Steering Linear Hydraulic Motor
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.
Page 75: Dismounting The Steering Unit
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.
Page 76: Removal Of The Hydraulic Tank
Steering Take out the steering hydraulic unit. Remove the hydraulic hoses on the steering unit. Avoid the oil soaking into the ground� Note D451465 When mounting the steering hydraulic unit back proceed in the reverse order and take care of the correct connection of the hy- draulic hoses.
Page 77 WORKSHOP MANUAL Remove the hydraulic hoses. Avoid the oil soaking into the ground� D451467 D451468 Remove the screws (3x). D451469 D451470 F80W...
Page 78: Mounting The Hydraulic Tank
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. D451469 D451470 Mount the hydraulic hoses. D451467 D451468 F80W...
Page 79: Adjustment Of The Front Wheel Turning Angle Indicator
WORKSHOP MANUAL 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 gauge (2). •...
Page 80 F80W...
Page 81: Travel
WORKSHOP MANUAL Travel F80W...
Page 82: Description Of Basic Elements
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...
Page 83 WORKSHOP MANUAL Setting the maximum pump volume DD451049 DD451050 Setting the neutral pump position DD451051 Coil of the brake valve electromagnet Y7 DD451052 F80W...
Page 84 Travel 10 Brake pressure switch D451053 11 Pump plate tilt sensor D451054 12 Travel hydraulic motor DD451055 13 Travel gearbox DD451056 F80W...
Page 85: Diagnostics
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 •...
Page 86: Measuring The Brake Valve Electromagnet Y7
Travel 9�2�2 Measuring the brake valve electromagnet Y7 Disconnect the connector from valve Y7. D451494 Measure the resistance between outputs of the electromagnet coil of approximately 6 Ω. D451498 F80W...
Page 87: Measuring The Refilling Pressure
WORKSHOP MANUAL Measure the opened circuit between individual outputs and the electromagnet body. D451499 9�2�3 Measuring the refilling pressure Measure the pressure using a pressure gauge with a suitable range. Connect the pressure gauge. D451500 Start the engine and set the engine speed adjusting controller to the maximum speed.
Page 88: Measuring The Maximum Pressure For Forward And Reverse Travel
Travel 9�2�4 Measuring the maximum pressure for forward and reverse travel 14-2SC DN08 Measure the pressure using a pressure gauge with a suitable 13-2SC DN08 range. Disable the brake release function. 22-1SC DN08 27-1SC DN08 451502 D451A503 Secure the machine against travel. Start the engine and set the engine speed adjusting controller to the maximum speed.
Page 89 WORKSHOP MANUAL D451506 Measure the maximum pressure to approximately 150 Bar. Note In case a different value is measured, contact your dealer or DY- NAPAC Technical Support. D451507 D451508 F80W...
Page 90: Measuring The Resistance Of The Electromagnet Coil
Travel 9�2�5 Measuring the resistance of the electromagnet coil Disconnect the connectors from the coils of electromagnets Y12 and Y13. Y12 – for forward travel Y13 – for reverse travel D451509 Measure the resistance of approximately 5.3 Ω between out- puts of the coil of electromagnets Y12 and Y13.
Page 91 WORKSHOP MANUAL D451513 Remove all hoses from the pump. D451514 D451515 Remove pump bolts. D451516 F80W...
Page 92: Dismounting The Hydraulic Motor And Travel Gearbox
Travel 9�4 Dismounting the hydraulic motor and travel gearbox Dismount the hydraulic motor 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 way on both sides of the machine.
Page 93 WORKSHOP MANUAL D451521 Remove the screws. D451A522 Remove the screws (8x). DD451023 F80W...
Page 94: Mounting The Hydraulic Motor And Travel Gearbox
Travel 9�5 Mounting the hydraulic motor and travel gearbox Mount the hydraulic motor and travel gearbox to the machine 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.
Page 95 WORKSHOP MANUAL Mount the rear wheels. Mount the screws. D451519 D451518 D451517 F80W...
Page 96 F80W...
Page 97: 10 Gear Pump
WORKSHOP MANUAL 10 Gear pump F80W...
Page 98: Description Of Basic Elements
Gear pump 10�1 Description of basic elements Gear pump D451574 Hydraulic block D451575 Linear hydraulic motors D451576 Vibrators D451577 F80W...
Page 99 WORKSHOP MANUAL Hydraulic motor for driving the augers and the belt conveyor D451578 Steering linear hydraulic motor DD451057 F80W...
Page 100: Diagnostics
D451579 STOP Let the belt conveyor function running for the maximum period of 2 sec� Measure the pressure of approximately 150 Bar. Note In case a different value is measured, contact your dealer or DYNAPAC Technical Support. D452013 D451580 F80W...
Page 101: Measuring The Screed Lifting Pressure
Set the engine speed setting switch (10) to the maximum speed (up position). STOP Let the engine idle for at least for 5 minutes� D452015 Measure the pressure of approximately 50 Bar. Note In case a different value is measured, contact your dealer or DYNAPAC Technical Support. D451581 F80W...
Page 102: Measuring The Screed Extension Pressure
– right (3) on the left during the meas- STOP urement. D452016 Measure the pressure of approximately 50 Bar. Note In case a different value is measured, contact your dealer or DYNAPAC Technical Support. D451581 F80W...
Page 103: Measuring The Maximum Vibrator Pressure
WORKSHOP MANUAL 10�2�4 Measuring the maximum vibrator pressure Measure the maximum vibrator pressure on the gear pump us- ing a suitable pressure gauge. D451632 Using the screed lift/lower switch (7) lift the screed to the maxi- mum position. STOP Set the travel controller (8) to the neutral position. Using the engine speed setting switch (10), set the maximum engine speed.
Page 104: Measuring The Vibration Frequency
Gear pump Measure the pressure of vibrators of approximately 50 Bar. Note In case a different value is measured, contact your dealer or DYNAPAC Technical Support. D451634 10�2�5 Measuring the vibration frequency Measure the vibration frequency using a suitable vibrometer. Start the engine.
Page 105: Dismounting The Gear Pump
WORKSHOP MANUAL 10�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. Avoid the oil soaking into the ground� D451452 Remove the screws.
Page 106: Dismounting The Vibration Units
Gear pump 10�4 Dismounting the vibration units STOP Start the engine. Adjust the maximum screed width with the controls (2) and (3) on the control panel. Turn off the engine, disconnect the battery disconnecter and close the gas bottle valve. D452020 Dismount the vibration units when the machine is parked on a ...
Page 107 WORKSHOP MANUAL Remove the screws. Note During reverse assembly glue the screws with the LOXEAL 83∙54 adhesive. D451955 D451956 F80W...
Page 108: Hydraulic System Switchboard
Gear pump 10�5 Hydraulic system switchboard 10�5�1 Description of basic elements 1E Brake electromagnet 2E Screed lowering electromagnet 3E Screed hydraulic system pressure safety valve 4E Vibration 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 –...
Page 109 WORKSHOP MANUAL D451059 F80W...
Page 110 F80W...
Page 111: 11 Cooling
WORKSHOP MANUAL 11 Cooling F80W...
Page 112: Description Of Basic Elements
Cooling 11�1 Description of basic elements Cooler Temperature sensor Output Input D451472 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. D451475 11�2�2 Temperature sensor Turn the key in the ignition box to the “I“...
Page 113: Dismounting The Cooler
WORKSHOP MANUAL 11�3 Dismounting the cooler Drain the oil from the hydraulic tank. Perform the hydraulic oil draining when the machine is parked on a flat and 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 drain plug (3).
Page 114 Cooling Remove the hoses of the input and output. D451479 Loosen the screw and move the horn to the side. D451480 Remove the screws. D451481 D451482 F80W...
Page 115: Mounting The Cooler
WORKSHOP MANUAL Remove the screws. D451483 D451484 11�4 Mounting the cooler Mount the cooler to the machine with the switched off battery disconnecter and with the closed gas bottle valve. Mount the screws. D451483 D451484 F80W...
Page 116 Cooling Mount the screws. D451481 D451482 Mount horn and tighten the screw. D451485 Mount the hoses of the input and output. D451479 F80W...
Page 117 WORKSHOP MANUAL Connect the connectors X41, X19 and X20. D451478 D451477 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 gauge (2).
Page 118 F80W...
Page 119: 12 Screed
WORKSHOP MANUAL 12 Screed F80W...
Page 120: Dismounting The Screed Lifting Cylinder
Screed 12�1 Dismounting the screed lifting cylinder STOP Start the engine and lower the screed to the ground. • Procedure for lowering of the screed in the transport mode: Set the travel controller (8) to the neutral position (N). Using the engine speed setting switch (10), set the maxi- mum engine speed.
Page 121 WORKSHOP MANUAL Plug both ends of the hose. D451584 Dismount the screwed fittings. D451589 D451590 F80W...
Page 122: Replacement Of Linear Hydraulic Motors For Screed Extension
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� D451591 Plug all ends. D451592 Remove the screw. D451593 F80W...
Page 123 WORKSHOP MANUAL Remove the pin. Note Proceed in the same way on the other side of the hydraulic motor. D451594 D451595 F80W...
Page 124: Basic Setting Of The Screed
Screed 12�3 Basic setting of the screed Park the machine on a flat and solid surface. Note Make sure that the machine is levelled by measuring the frame distance from the ground – 12.5 cm – at the front wheel. D451604 If a different distance is measured, adjust the height of the front wheel to the required height.
Page 125 WORKSHOP MANUAL Start the engine and lower the screed to the ground by selector switch (7). STOP D452022 D451606 Set the distance of 13–13.5 cm from the ground to the screw centre by the paving thickness controller (47) on both sides. 451092 DD451035 F80W...
Page 126 Screed Note Ensure that the paving thickness controllers (47) face to the ground on both sides. DD451036 Loosen the screws (3x). D451608 Using the adjusting nuts, set the height of the hydraulic exten- sion to 2 mm above the main screed. Lock the screws (3x).
Page 127: Replacement Of The Friction Plates
WORKSHOP MANUAL 12�4 Replacement of the friction plates Description Central base plate (1x) D451066 Central cover plate (1x) D451067 Rear base plate (2x) D451068 2x Rear cover plate (4) D451069 F80W...
Page 128: Front Frame
Screed 12�4�1 Front frame Preparation Weld the central cover plate (2) to the central base plate (1). D451070 Fill the slots with welding Remove the excess weld The plan must be smoothand at D451075 Procedure Remove the welds. D451071 D451072 F80W...
Page 129 WORKSHOP MANUAL Remove the central base plate. D451073 Install the new base plate. D451074 Check the dimensions. The base plate must be centred. 16 mm D451076 16 mm D451077 F80W...
Page 130 Screed Weld the base plate to the frame. D451078 D451079 D451080 D451081 F80W...
Page 131: Rear Frames
WORKSHOP MANUAL 12�4�2 Rear frames 3x20(20) Preparation Weld the rear cover plate 2x (4) to the rear base plate 2x (3). D451082 Fill with welding Remove the excess weld Procedure The plan must be smooth and at D451083 Remove the welds. D451084 D451085 D451086...
Page 132 Screed Remove the rear base plates. D451088 D451089 Install the new rear base plates. D451090 D451091 F80W...
Page 133 WORKSHOP MANUAL Check the alignment. The base plates must be centred. D451092 D451093 Weld the base plates to the frame. a3 50 a3 50 a3 40 a3 40 a3 40 a3 40 D451094 D451095 D451096 D451097 F80W...
Page 134 F80W...
Page 135: 13 Screed Gas Heating
WORKSHOP MANUAL 13 Screed gas heating F80W...
Page 136: Gas System Diagram
Screed gas heating 12 V D451900 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 Gas hose 10 Reducing valve 11 Screed heating fuse, 5 A 12 Safety valve...
Page 137: Ignition Process
WORKSHOP MANUAL 13�2 Ignition process When the screed heating switch is switched on: • The control unit opens solenoid valves to supply gas to the burners. • The control unit activates ignition units and unless perma- nent fire is achieved within 7 seconds, the electronic system indicates a fault.
Page 138 Screed gas heating Potential faults: Problem in electrical wiring • Proceed according to Chapters: Coil electromagnet resistance measurement (13.8.2) Gas supply valve coil power supply measurement (13.8.3) Spark plug check procedure (13.11.2) Temperature sensor (13.12) High-voltage cables (13.10) Measuring resistance on the ignition unit (13.9.1) Voltage measurement on the cable harness of ignition units (13.9.2).
Page 139: Diagnostics
WORKSHOP MANUAL 13�3 Diagnostics 13�3�1 Gas equipment tightness check Check the gas equipment for leakage when the machine is parked on a flat and solid surface and the valve (5) of the gas bottle is open. Measure the gas leak on gas components where there is a dan- ger of a gas leak.
Page 140 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 equipment repaired by an authorised service plant or qualified personnel.
Page 141: Reducing Valve
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�...
Page 142 Screed gas heating Loosen the fittings (5x). D451613 Remove the screws (2x). D451614 D451615 F80W...
Page 143: Screed Heating Burner
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.
Page 144: Cleaning The Gas Burner Nozzle
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.
Page 145 WORKSHOP MANUAL Clean the nozzle hole with a suitable wire. D451602 D451603 F80W...
Page 146: Gas Flame Adjustment
Screed gas heating 13�7�3 Gas flame adjustment STOP 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.
Page 147: Test Of Burner Ignition
WORKSHOP MANUAL 13�7�4 Test of burner ignition STOP 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.
Page 148 Screed gas heating 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�...
Page 149: Gas Supply Solenoid Valves
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.
Page 150: Measuring Resistance Of The Coils Of Gas Supply Valve Electromagnets
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.
Page 151: Measuring Power Supply Of The Coils Of Gas Supply Valve Electromagnets
WORKSHOP MANUAL 13�8�3 Measuring power supply of the coils of gas supply valve electromagnets STOP 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. D452026 Measure the battery voltage (12 V) on the sockets of electro- magnets Y14 and Y15 between pins 1 and 2.
Page 152: Ignition Units
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.
Page 153: Voltage Measurement On The Cable Harness Of Ignition Units
WORKSHOP MANUAL 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“...
Page 154: High-Voltage Cables
Screed gas heating Switch on the gas screed heating system by moving the switch (13) to the upper position. STOP Measure the voltage of the battery (12 V) between the pin of the frame and pins 2 and 3. D452028 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.
Page 155: Spark Plug Check Procedure
WORKSHOP MANUAL 13�11�2 Spark 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).
Page 156: Temperature Sensor
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.
Page 157: 14 Belt Conveyors And Augers
WORKSHOP MANUAL 14 Belt conveyors and augers F80W...
Page 158: Replacement Of The Hydraulic Motor For Driving The Augers And The Belt Conveyor
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.
Page 159 WORKSHOP MANUAL D421528 Remove the tension screw. D421529 Remove the screw for fastening the tension mechanism of the auger chain. D421530 D421531 F80W...
Page 160 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 F80W...
Page 161: Dismounting The Belt Conveyor Chain
WORKSHOP MANUAL 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.
Page 162 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.
Page 163 WORKSHOP MANUAL • Remove the screw. D451543 • Remove the screw and the washer. D451544 • Remove the lock ring. D451545 • Remove the gear wheels. D451546 F80W...
Page 164 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 F80W...
Page 165: Mounting The Belt Conveyor Chain
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).
Page 166 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.
Page 167 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.
Page 168 Belt conveyors and augers • Mount the rear wheels on the left and right side of the ma- chine. D451519 D451518 D451517 F80W...
Page 169: Setting The Belt Conveyor Chain Sag
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.
Page 170 Belt conveyors and augers Belt tension check: • Check chain movement. Start the engine. • Let the conveyor running in the manual mode. • Check the correct running of conveyor chains. • Stop 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�...
Page 171: Dismounting The Belt Conveyor Chain Drive
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.
Page 172 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.
Page 173 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 F80W...
Page 174: Dismounting The Auger Chain
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.
Page 175 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.
Page 176 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 F80W...
Page 177: Replacement Of The Drive Switch Of Augers And Belt Conveyor
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.
Page 178: Measuring The Belt Conveyor Drive Switch S7
Belt conveyors and augers 14�7�1 Measuring the belt conveyor drive switch S7 Voltage measurement • Disconnect the connector X43. • Turn the key in the ignition box to the “I“ position. • Measure the voltage of 9.9 V on the connector on the cable harness side.
Page 179: Dismounting The Driving Gear Wheel Of Augers
WORKSHOP MANUAL 14�8 Dismounting the driving gear wheel of augers Dismount the driving 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. D451549 Remove the screws on the right and left side (4x).
Page 180: Replacement Of Consumables
Belt conveyors and augers 14�9 Replacement of consumables 14�9�1 Belt conveyor chain guide plate Replace the belt 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.
Page 181 WORKSHOP MANUAL Remove the screws (3x). D451560 D451559 Remove the rear shaft with gear wheels. • Loosen the tension screws on the left and right side. D451558 • Remove the bearing housing on the left and right side. D451561 F80W...
Page 182 Belt conveyors and augers • Pull out the shaft with the gear wheels. D451562 Remove the front shaft with gear wheels. • Loosen the screws on both sides of the machine. D451563 • Remove chain tensioners. D451564 • Remove the shaft out of the machine. D451565 F80W...
Page 183 WORKSHOP MANUAL Having the front wheel levelled, completely screw the adjusting mechanism of the front wheel height. Take out the guide plate of the belt conveyor chain and replace it with the new one. D451566 Mount the front shaft and the chain tensioners. D451564 Mount the rear shaft and the bearing housing on the left and right side.
Page 184 Belt conveyors and augers Mount the belt conveyor chain according to Chapter 14.3. Note Ensure that the conveyor chain is installed with the contact sur- face to the chain guide plate. 451567 D451568 Ensure that the chain is at the same distance from the machine frame on both sides.
Page 185 WORKSHOP MANUAL Tighten the screws of the front shaft on both sides of the ma- chine. D451563 Mount the screws (3x). D451560 D451559 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- verse order according to Chapter 14.5.
Page 186: Cover Plates
Belt conveyors and augers Mount the rear wheels on the left and right side of the machine. • Mount the screws. D451519 D451518 D451517 14�9�2 Cover plates Remove the screws (8x). Note During reverse assembly glue the screws with the LOXEAL 83∙54 adhesive.
Page 187: 15 Wiring
WORKSHOP MANUAL 15 Wiring F80W...
Page 188: Description Of Basic Components
Wiring D451647 15�1 Description of basic components Main harness Battery cable Gas ignition cable Beacon cable Foot switch cable F80W...
Page 189: Central Earthing Points X6 And X7
WORKSHOP MANUAL 15�1�2 Central earthing points X6 and x7 Location of earthing points. DD451042 DD451043 Numbering of pins. DD451044 F80W...
Page 190: Diagnostics
Wiring 15�2 Diagnostics Perform diagnostics of electrical wiring on the machine with the closed gas bottle valve. 15�2�1 List of error codes displayed on the display Code F Short description Causes and troubleshooting hydraulic oil sensor short circuit to ground detected – check wiring (X41, RD 141, WH 227) material flow sensor short circuit to ground detected –...
Page 191 WORKSHOP MANUAL Code F Short description Causes and troubleshooting floating valve short circuit to ground or battery or no connection detected – check wiring and coil (X61, Y8, WH 258, WH 259) floating safety short circuit to ground or battery or no connection detected – check wiring and coil (X61, Y8, WH 258, WH 259) screed enable valve short circuit to ground or battery or no connection detected –...
Page 192 Wiring Code F Short description Causes and troubleshooting heating switch short circuit to ground detected – check wiring (X50, S14, RD 150, WH 239) ignition 1 misfire ignition box 1 indicates misfire – check gas flow and burner ignition 1 (X73, X76, I1) ignition 2 misfire ignition box 2 indicates misfire –...
Page 193: Fuse Box
WORKSHOP MANUAL 15�2�2 Fuse box Diagnostics connector Diagnostic connector of the engine 452052 Fuse at the input of the power supply of the control unit ..........(3 A) Fuse at the output of the power supply of the control unit .............. (25 A) Oil cooler fan fuse ..........
Page 194: Diagnostics Socket
Wiring 15�2�3 Diagnostics socket Location of the diagnostic socket. D451648 Basic description of the diagnostic socket. CAN-Low (pin 7) CAN-High (pin 2) DD451062 F80W...
Page 195: Measuring Of The Can Bus Data Bus
WORKSHOP MANUAL 15�2�3�1 Measuring of the CAN BUS data bus Measure 2.5 – 3.5 V at the diagnostic socket of CAN-High pin (2). Measure 1.5 – 2.5 V at the diagnostic socket of CAN-Low pin (1). 3,5V 2,5V 1,5V DD451027 15�2�3�1�1 Measuring voltage of the CAN BUS data bus Turn the key in the ignition box to the “I“...
Page 196: Communication With The Control Unit A2 By Means Of Bodas - Service 3.5
Wiring 15�2�4 Communication with the control unit A2 by means 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 •...
Page 197 WORKSHOP MANUAL Connect the computer to the machine using the connecting cable (1). D451C001 Connect the USB key (2) to the computer. D451C002 Start the Bodas software. D451C004 Turn the key in the ignition box to the “I“ position. 380K0022 F80W...
Page 198 Wiring Press the “Scan” icon for connecting the computer. D451C005 Press the button to confirm licence conditions. D451C006 The computer is connecting. Number of found controllers: 0 Scannin for controllers D451C007 F80W...
Page 199: Uploading And Deleting Errors
WORKSHOP MANUAL 15�2�4�2 Uploading and deleting errors 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. SN: 00056112 RC28-14/30 Unroll the “Error Messages” tab. HwCode:0000O6 AFW150-2 Errors detected...
Page 200: Check Of Parameters
Wiring 15�2�4�3 Check of parameters The check of parameters serves for the evaluation of faults or for checking the values on inputs and outputs of the RC unit. There are two ways how to display the values. Method No� 1 Display the “I/O Status view”...
Page 201: Display Measurement
WORKSHOP MANUAL 15�2�5 Display measurement Disconnect connectors X33 and X40 from display A3. Measure a resistance of approximately 60 Ω on the connector X40 between the blue and yellow wire. D452029 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.
Page 202: Foot Switch Measurement
Wiring 15�2�6 Foot switch measurement Disconnect the connector X44 of the foot switch S8. Measure the resistance on the connector X44 on the switch side between pin A and pin B. The measured value will be displayed after activating the foot switch. DD451010 Turn the key in the ignition box to the “I“...
Page 203: Travel Controller Measurement
WORKSHOP MANUAL 15�2�7 Travel controller measurement In 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 D451461 •...
Page 204 Wiring • Disconnect the connector X36 Measure the voltage on the connector X36 on the machine side: • approximately 2.71 V between pin 14 and pin 3. • approximately 5.08 V between pin 14 and pin 7. • approximately 2.71 V between pin 14 and pin 8. •...
Page 205: Paving Speed Selector Measurement
WORKSHOP MANUAL 15�2�8 Paving speed selector measurement Measure the paving 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. D451461 Remove the screw.
Page 206 Wiring • Remove the paving speed selector regulator. Loosen the screw. D452034 DD451015 Remove the nut. DD451016 F80W...
Page 207 WORKSHOP MANUAL – Slightly pull out the selector and disconnect the X37 connec- tor. DD451017 Measure the resistance of the paving speed selector. • 6.2 Ω between pin 1 and pin 3 • 5.5 Ω between pin 1 and pin 2 in the minimum selector position •...
Page 208: Calibration
Wiring 15�3 Calibration Perform 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. 451C003 Connect the computer to the machine using the connecting cable (1). D451C001 Connect the USB key to the computer (2).
Page 209: Calibration Of The Travel Controller And The Paving Speed Selector
WORKSHOP MANUAL Turn the key in the ignition box to the “I“ position. 380K0022 15�3�2 Calibration of the travel controller and the paving speed selector Press the “Scan” icon for connecting the computer. D451C005 Press the button to confirm licence conditions. D451C006 F80W...
Page 210 Wiring The computer is connecting. Number of found controllers: 0 Scannin for controllers D451C007 Unroll the “Parameter” tab. RC28-14/30 SN: 00065112 HwCode: 0000D6 AFW150-2 Parameter Processdata I/O Status view Custom view D451C008 Select – 1.8 “Calibration operation” Confirm – 1.8.1 “Calibrate” 1.8 Calibration operation Minimum Maximum...
Page 211 WORKSHOP MANUAL Confirm it by pressing the “Set min value” button. The red highlighting means that the value has been changed. 1.8 Calibration operation Minimum Maximum Current 1.8.1 driving lever Set min value Cancel 0.57V 3.97V 0.56V Saved Current 1.8.2 driving lever middle Accept Adjust 2.20V...
Page 212 Wiring Set the neutral position by the travel controller. STOP D452035 Confirm it by pressing “Adjust”. The current value will be saved. 1.8 Calibration operation Minimum Maximum Current 1.8.1 driving lever Set max value Cancel 0.57V 3.97V 4.12V Saved Current Accept Adjust 1.8.2 driving lever middle...
Page 213 WORKSHOP MANUAL Calibrate the paving speed selector by pressing the “Calibrate” button. 1.8 Calibration operation Minimum Maximum Current 1.8.1 driving lever Accept Calibrate 0.61V 4.09V - - - Saved Current 1.8.2 driving lever middle Accept Adjust 2.24V 2.24V Minimum Maximum Current Accept Calibrate...
Page 214: Travel Pump Calibration
With the motor running, heat up the hydraulic oil to the tem- perature of 40°C. 451C003 Before starting calibration, enter the password. Note To obtain the password to the Bodas – service 3.5 system, con- tact your dealer or the DYNAPAC Technical Support. D451C023 F80W...
Page 215 WORKSHOP MANUAL A new connection will be uploaded. D451C024 Unroll the “Parameter” tab and select “1.7 Calibration drive”. Parameter Learning curves 1.6 Brake 1.7 Calibration drive 451C025 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”.
Page 216 Wiring Check the last box in “1.7.8 Set value”. The line will become red and the value will be changed to “1”. 1.7.7 Propel pump calib 1.7.8 Set value D451C028 Uncheck the last box in “1.7.8 Set value”. A short sound signal will be heard in case of correct setting. 1.7.7 Propel pump calib 1.7.8 Set value D451C029...
Page 217 WORKSHOP MANUAL Slowly turn the paving speed selector (14) to the “max” position. STOP D452038 Confirm the setting by checking and subsequent unchecking the box in “1.7.8 Set value”. A short sound signal is heard. 1.7.7 Propel pump calib 1.7.8 Set value D451C029 Turn the paving speed selector (14) to the “min”...
Page 218 Wiring Confirm the setting by checking and subsequent unchecking the box in “1.7.8 Set value”. A short sound signal is heard. 1.7.7 Propel pump calib 1.7.8 Set value D451C029 Activate the foot switch (48). 451686 Shift the travel controller (8) to the reverse travel position. Slowly turn the paving speed selector (14) so that the machine STOP drives at the lowest possible speed (the wheels are permanently...
Page 219 WORKSHOP MANUAL Slowly turn the paving speed selector (14) to the “max” position. STOP D452038 Confirm the setting by checking and subsequent unchecking the box in “1.7.8 Set value”. A short sound signal is heard. 1.7.7 Propel pump calib 1.7.8 Set value D451C029 Turn the paving speed selector (14) to the “min”...
Page 220 Wiring Confirm the setting by checking and subsequent unchecking the box in “1.7.8 Set value”. A short sound signal is heard. 1.7.7 Propel pump calib 1.7.8 Set value D451C029 After finishing calibration uncheck the last box in “1.7.7 Propel pump calib”. 1.7.7 Propel pump calib 1.7.8 Set value D451C026...
Page 221: Control Unit A2
WORKSHOP MANUAL 15�4 Control unit A2 When replacing the control unit, the machine compatibility with the software in the control unit must be consulted with the DY- NAPAC Technical Support. Software AFW150-2 v1.2.2 D451650 Control unit nameplate. Rexroth Made in Germany 1312 1649 R 917 007 18-06-01...
Page 222: Connector Of The Control Unit
Wiring 15�4�1 Connector of the control unit D451065 Description of the connector Connector X34 Connector X35 Pin 101 - 194 Pin 201 - 258 F80W...
Page 223: Dismounting The Control Unit A2
WORKSHOP MANUAL 15�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 X35 of the control unit. D451653 Remove the screws (4x).
Page 224: Display Unit
Wiring 15�5 Display unit If the display does not respond when the key is turned to the “I” position, check: • fuse F7 (2 A) • wiring between the ignition box S3 (pin 15) and the display connector X33 (pin 1) •...
Page 225 WORKSHOP MANUAL Remove the plate on the control panel: • Remove the screws (3x). D452047 Remove the lock nuts (2x). Note Proceed in the reverse order when reassembling the display. DD451005 F80W...
Page 226: Travel Controller
Wiring 15�6 Travel controller When calibrating the travel controller proceed 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 valve. Remove the steering wheel.
Page 227 WORKSHOP MANUAL Remove the plate on the control panel: • Remove the screws (3x). D452047 Disconnect the connector X36. DD451012 Remove screws of the travel controller (4x). Note Proceed in the reverse order when reassembling the unit. After reassembling the unit perform calibration according to Chapter 15.3.2.
Page 228: Paving Speed Selector
Wiring 15�7 Paving speed selector • In case of a fault of the paving speed selector, the display shows error message F12. • When calibrating the paving speed 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 closed gas bot- tle valve.
Page 229 WORKSHOP MANUAL Remove the paving speed selector regulator. – Loosen the screw. D452034 DD451015 Remove the nut. DD451016 Slightly pull out the selector and disconnect the X37 connector. Note Proceed in the reverse order when reassembling the unit. After reassembling the unit perform calibration according to Chapter 15.3.2.
Page 230: Battery
Wiring 15�8 Battery Measuring the battery voltage. Battery status Battery voltage Battery charge status 12.6+ V 100% 12.5 V 12.42 V 12.32 V DD451020 12.20 V 12.06 V 11.9 V 11.75 V 11.58 V 11.31 V 10.5 V F80W...
Page 231: 16 Appendices
WORKSHOP MANUAL 16 Appendices F80W...
Page 232: Machine Wiring Diagram
Appendices 16�1 Machine wiring diagram Legend: A1 Diesel engine S7 Travel switch A2 BODAS RC control unit S8 Foot switch A3 Display unit S9 Horn button A4 Travel control lever S10 Left smoothing screed extension switch A5 Diagnostic socket S11 Right smoothing screed extension switch A6 Screed heating unit 1 (left) S12 Smoothing screed lifting switch A7 Screed heating unit 2 (middle)
Page 233 WORKSHOP MANUAL X1.1:6 N.C. X1.1:1 12V 77Ah X1.1:2 X8: B+ X17: 3 X1.2:1 N.C. X1.1:3 X1.1:4 X1.2:5 X1.2:6 X1.2:2 X1.1:5 X17: 1 X6: 14 49 Fuel valve - 50 Fuel valve + 18 Senzor GND 35 Oil temp. X35:23 BAT + Gas ignition 1 2 Speed - X34:48...
Page 234 Appendices Machine wiring diagram Legend: A1 Diesel engine S7 Travel switch A2 BODAS RC control unit S8 Foot switch A3 Display unit S9 Horn button A4 Travel control lever S10 Left smoothing screed extension switch A5 Diagnostic socket S11 Right smoothing screed extension switch A6 Screed heating unit 1 (left) S12 Smoothing screed lifting switch A7 Screed heating unit 2 (middle)
Page 235 WORKSHOP MANUAL X7: 9 X34:52 X35:11 X7: 10 X34:76 X35:35 Engine working speed X7: 11 X34:51 X34:53 X35:52 Driving lever reverse X34:57 X34:77 Driving lever forward X34:44 X34:83 Driving lever neutral X34:64 Driving lever POT wiper X34:21 X34:46 X34:45 X35:31 Driving lever POT wiper redundancy X35:40 X34:66...
Page 236 Appendices Machine wiring diagram Legend: A1 Diesel engine S7 Travel switch A2 BODAS RC control unit S8 Foot switch A3 Display unit S9 Horn button A4 Travel control lever S10 Left smoothing screed extension switch A5 Diagnostic socket S11 Right smoothing screed extension switch A6 Screed heating unit 1 (left) S12 Smoothing screed lifting switch A7 Screed heating unit 2 (middle)
Page 237 WORKSHOP MANUAL X7: 17 X7: 18 X6: 6 X6: 15 X76: 1 X73: 1 X6: 8 X77: 1 X74: 1 X6: 10 X78: 1 X75: 1 X6: 12 X6: 13 X33: 5 X33: 1 X40: 6 X40: 7 40419B_3en F80W...
Page 238: Electric Installations Cable Harnesses
Appendices 16�2 Electric installations cable harnesses Main harness ..............40744 F80W...
Page 239 F80W F80W HARNESS Svazek Objednávací číslo 4-40744 Part Number 40744 LEGENDA: CABLE HARNESS LEGEND: 1062-16-0122 1062-16-0122 1062-16-0122 1062-16-0122 MWTM 25/8 1000/172 - 50mm 44.20911 2ks svorka 2pcs crimp 2ks svorka 2pcs crimp WH 1 - WH 1 - WH 0.75 - 340 D SUB 31819-0 1ks spojka 31819-0 1pcs Coupler...
Page 240: Machine Hydraulic System Diagram
Appendices 16�3 Machine hydraulic system diagram Legend: 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 hydraulic cylinder 10 Left paving width hydraulic cylinder 11 Right paving width hydraulic cylinder 12 Control unit...
Page 241 WORKSHOP MANUAL 451190 F80W...
Page 242: Measuring Points Of The Hydraulic Circuit
Appendices 16�3�1 Measuring points of the hydraulic circuit The table shows the list of the hydraulic circuit measuring points located on the machine. Note See the procedure for measuring the pressure in the hydraulic circuit in the workshop manual delivered upon a special order. Pressure Mode (bar)
Page 243: Screed Gas Heating System Diagram
WORKSHOP MANUAL 12 V D451900 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 hose 9 Gas hose 10 Reducing valve 11 Screed heating fuse, 5 A...
Page 244 Appendices Notes F80W...
Page 246 www.dynapac.com...

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