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Fayat Group Dynapac F80W Operating Manual

Asphalt paver wheeled
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OPERATING MANUAL
Asphalt paver wheeled
F80W
Hatz
4812077835

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  • Page 1 OPERATING MANUAL Asphalt paver wheeled F80W Hatz 4812077835...
  • Page 3 F80W Asphalt paver, wheeled Hatz Operating Manual Edition 07/2022 EN From Serial No. 3038458 Original Operating Manual...
  • Page 7 Congratulations to purchasing a new DYNAPAC machine. This modern machine is characterised by simple operation and easy mainte- nance. In order to avoid faults due to improper operation and maintenance, we request that you read this Operating Manual with great care and keep them for later reference. With kind regards, Dynapac GmbH | Ammerlaender Str.
  • Page 8 Preface Information, specifications, and recommended operation and maintenance instructions contained in this publication are basic and final information at the time of the printing of this publication. Printer’s errors, technical modifications, and modifications of figures are reserved. 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.
  • Page 9 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 10: Table Of Contents

    Contents Contents ................................4 SPECIFICATION MANUAL ........................9 1.1 Basic data ..............................10 1.2 Dimensional drawing of the machine ....................12 1.3 Technical data ............................14 1.3.1 Specification table .........................................14 1.3.2 Machine gradeability and lateral static stability ............................16 1.3.3 Optional equipment ......................................18 1.3.3.1 Screed vibration units ......................................19 1.3.3.2 Mechanical screed extension ....................................20 1.3.3.3 Dual wheels ..........................................22 1.3.3.4 Front wheel scraper ......................................23...
  • Page 11 OPERATING MANUAL 2.3 Machine disposal ..........................57 2.3.1 Machine disposal after its service life ................................57 2.4 Machine description ..........................58 2.4.1 Description of main parts of the machine and screed ..........................59 2.4.2 Main dashboard ........................................63 2.4.3 Display ............................................67 2.4.4 Foot switch ..........................................69 2.5 Operation of the machine ........................71 2.5.1 Turning ON/OFF the battery disconnecter ..............................71...
  • Page 12 Contents MAINTENANCE MANUAL ........................121 3.1 Safety and other measures during maintenance of the machine ..........123 3.1.1 Safety precautions during machine maintenance ..........................123 3.1.2 Safety and fire precautions during replacement of operating fluids ....................124 3.1.3 Environmental and hygienic principles ..............................125 3.1.3.1 Hygienic principles ......................................
  • Page 13 OPERATING MANUAL Every 100 hours of operation ......................156 3.6.16 Fuel system tightness check ................................... 156 3.6.17 Rear wheel fastening check .................................... 157 3.6.18 Conveyor chain tensioning ..................................... 158 Every 250 hours of operation ......................159 3.6.19 Engine oil replacement ..................................... 159 3.6.20 Engine air intake check .....................................
  • Page 14 F80W...

  • Page 15: Specification Manual

    SPECIFICATION MANUAL 1 SPECIFICATION MANUAL F80W (Hatz) F80W...

  • Page 16: Basic Data

    Basic data Machine description Machine type The F80W wheeled asphalt paver is equipped with a screed with gas heating. The basic paving width is from 800 mm (31.5 in) to ........................ 1,300 mm (51.2 in). Serial number of the machine The machine is characterised with good manoeuvrability, good view from the operator's place, a wide range of uses and easy transport.
  • Page 17 SPECIFICATION MANUAL The machine that complies with the requirements on health protection and safety is provided with a  nameplate with CE marking. AMMERLAENDER STR. 93 1. Name – always stated only in the English version D-26203 WARDENBURG GERMANY 2. Type 3.

  • Page 18: Dimensional Drawing Of The Machine

    Dimensional drawing of the machine 452076 F80W...
  • Page 19 SPECIFICATION MANUAL 1280 2070 2680 1598 2865 2526 2550 50,4 81,5 105,5 62,9 112,8 99,4 100,4 1150 1699 30,1 25,2 31,5 45,3 66,9 F80W...

  • Page 20: Technical Data

    Technical data 1.3.1 Specification table F80W EU Stage V, U.S. EPA Tier 4f Weight Operating weight EN 500-1+A1 (CECE; including: screed extension, doubled driving wheels, vi- kg (lb) 1260 (2780) bration) Operating load EN 500-1+A1 (CECE) on the front axis kg (lb) 170 (370) Operating load EN 500-1+A1 (CECE) on the rear axis...
  • Page 21 SPECIFICATION MANUAL F80W EU Stage V, U.S. EPA Tier 4f Brakes Operating Hydrostatic Parking mechanical Emergency mechanical Fluid capacities Fuel l (gal US) 5 (1,3) Engine (oil filling) l (gal US) 2,2 (0,6) Hydraulic system l (gal US) 20 (5,3) Lubricating substances kg/lb 0,1 (0,22)

  • Page 22: Machine Gradeability And Lateral Static Stability

    Technical data 1.3.2 Machine gradeability and lateral static stability Always select the travel speed and the movement of the machine on a slope with regard to the safety of the ma- chine operator, other persons moving in the vicinity of the machine, the slope and the adhesion conditions.
  • Page 23 SPECIFICATION MANUAL Machine descent with a  full hopper (screed in the lower posi- tion). α = 14° (25%) 452075 Lateral static stability with an empty and full hopper. α = 12° (21%) D451175 F80W...

  • Page 24: Optional Equipment

    Technical data 1.3.3 Optional equipment Chapter Optional equipment Order number 1.3.3.2 Mechanical screed extension 4812061017 1.3.3.3 Dual wheels 4812061018 1.3.3.4 Front wheel scraper 4812061021 1.3.3.5 Material hopper extension 4812061019 1.3.3.6 Additional lighting 4812061020 1.3.3.7 Screed copying system 4812335000 F80W...

  • Page 25: Screed Vibration Units

    SPECIFICATION MANUAL 1.3.3.1 Screed vibration units The purpose of the screed vibration function is to: • lower the frictional resistance between the screed and the paved material during paving, • improve the surface of the paved asphalt mixture. Mount the screed vibration units according to the Mounting Manual.

  • Page 26: Mechanical Screed Extension

    Technical data 1.3.3.2 Mechanical screed extension The mechanical screed extension serves for extending the pa- ving width. The maximum width of the screed is 1,300 mm. After installing the mechanical screed extension set, the maximum screed wi- dth will increase by 350 mm to 1,650 mm. Paving width with mechanical extension is: •...
  • Page 27 SPECIFICATION MANUAL Setting the paving width Procedure for setting the required paving width on the left STOP side of the screed: To increase the paving width on the left side, turn the paving width switch (2) to the left and hold it. Once released, the paving width switch (2) returns to the middle position and the screed stops in the required position.

  • Page 28: Dual Wheels

    Technical data 1.3.3.3 Dual wheels Dual wheels serve for the improvement of machine traction and stability. A  dual wheel, which is part of the dual wheel set, is identical with the standard rear wheel. Distance between external surfaces of rear wheels: •...

  • Page 29: Front Wheel Scraper

    SPECIFICATION MANUAL 1.3.3.4 Front wheel scraper The scraper (1) is located on the swing fork of the front wheel and serves for cleaning the front wheel from gross dirt. Mount the scraper according to the Mounting Manual. Front wheel scraper kit D451817 Order no.: 4812061021 The front wheel scraper kit consists of the following com-...

  • Page 30: Material Hopper Extension

    Technical data 1.3.3.5 Material hopper extension The material hopper extension serves for enlarging the filling space and easier feeding of material to the machine. The material hopper extension consists of two plates (1) and (2), which are fitted with two fork-shaped holders (3) Mount the material hopper extensions according to the Mounting Manual.

  • Page 31: Additional Lighting

    SPECIFICATION MANUAL 1.3.3.6 Additional lighting Additional lighting (1) serves for lighting the area of the screed and augers. Mount the additional lighting according to the Mounting Manual. D451819 Additional lighting kit Order number: 4812061020 The additional lighting kit consists of the following compo- nents: •...

  • Page 32: Screed Copying System

    Technical data 1.3.3.7 Screed copying system The screed copying system (2) is used to set a constant paving thickness with the guide surface (e.g. the original paved layer). Before paving, fill the area in front of the screed with a sufficient amount of paving material.
  • Page 33 SPECIFICATION MANUAL Notes F80W...
  • Page 34 Notes F80W...

  • Page 35: Operating Manual

    OPERATING MANUAL 2 OPERATING MANUAL F80W (Hatz) F80W...

  • Page 36: Main Safety Precautions

    Main safety precautions 2.1.1 Obligations before putting into 2.1.2 Assurance of safety precautions by the operation owner Before starting working with the machine, the machine opera- He must ensure that the machine is operated only under conditi- tor and the machine operator shall read this Operating Manual ons and only for purposes it is technically capable for according and make themselves familiar with the operation of the machi- to conditions set by the manufacturer and respective standards.

  • Page 37: Requirements For Qualified Personnel

    OPERATING MANUAL 2.1.3 Requirements for qualified personnel All activities on the machine may only be performed by qualified, instructed and trained personnel. Qualified, instructed and trained personnel shall: • be over 18 years old, • trained in the provision of first aid and be able to provide it, •...

  • Page 38: Machine Operator's Obligations

    Main safety precautions 2.1.4 Machine operator's obligations Before starting operation of the machine, the driver is obliged After a warning alarm, the operator may put the machine into to get familiar with instructions stated in the documentation operation only when all workers have left the endangered area supplied together with the machine, especially with safety pre- and are at a safe distance from the machine.

  • Page 39: Screed Operators' Obligations

    OPERATING MANUAL 2.1.5 Screed operators' obligations Before starting operation of the machine, screed operators are The operator must carry out the machine maintenance in com- obliged to get familiar with instructions stated in the documen- pliance with instructions specified in the Operating manual. tation supplied together with the machine, especially with safe- The screed operator is obliged to equip the machine with acce- ty precautions, and strictly observe the instructions.

  • Page 40: Driver's Stand And Screed Operator Stand During Machine Operation

    Main safety precautions 2.1.6 Driver's stand and screed operator stand during machine operation These requirements during operation of the machine are considered binding with regard to the safety of people. Firstly, the machine operator and the screed operators must observe the below-given requirements during ma- chine operation.

  • Page 41: Dangerous Zone And Safe Distance

    OPERATING MANUAL 2.1.7 Dangerous zone and safe distance D451028 Dangerous zone of the machine: During the operation of the machine and paving no people may be present and stay in the dangerous zone of the machine. The dangerous zone of the machine (1) may only be entered into for the purpose of maintenance and cleaning of the machine when the conditions below are met: •...
  • Page 42 Main safety precautions Safe distance between a public road, the place of paving and the construction site: The safe distance between a public road, the place of paving and the construction site must be marked with a visible barrier against unauthorised access of other people to the place of paving and construction site. The safe distance between a public road, the place of paving and the construction site is determined by the machine user on the basis of respective national regulations.
  • Page 43 OPERATING MANUAL Safe distance of workers at the place of paving: All workers present at the place of paving, moving near the machine, but not directly operating the machine, must observe the mini- mum safe distance of 5 metres from the machine. The machine user as well as the machine operator must ensure adherence to the aforementioned safe distance of 5 m from the machine with regard to safety of workers at the place of paving.

  • Page 44: Machine Operation At Unclear Working Areas

    Main safety precautions 2.1.8 Machine operation at unclear working areas The machine operator may not operate the machine if he does not have a sufficient overview of the workplace and potential obstacles are not clearly visible. In such cases, a different efficient form of connection between the appointed worker and the machine operator must be ensured.
  • Page 45 OPERATING MANUAL EXAMPLES OF HAND SIGNALS: Start the engine 0040 Turn off the engine 0041 Stop STOP 0031 Watch out 0032 F80W...
  • Page 46 Main safety precautions Watch out, danger 0033 Machine travel 0034 Drive slowly forward – towards me 0035 Drive slowly backward – away from me 0036 F80W...
  • Page 47 OPERATING MANUAL Machine travel – to the right 0037 Machine travel – to the left 0038 Machine travel for a short distance 0039 F80W...

  • Page 48: Safety Notices And Symbols Used On The Machine

    Main safety precautions 2.1.10 Safety notices and symbols used on the machine D452050A F80W...
  • Page 49 OPERATING MANUAL Keep a safe distance! Danger zone 2939 2942bz Keep a safe distance! Danger of injury due to augers. 0045 There is a risk of electric shock. Risk of injury and electric shock. 0019 Get perfectly familiar with the machine operation and Read the operating maintenance according to the Operating Manual! manual...
  • Page 50 Main safety precautions 2586 Do not touch hot parts of the machine unless you make sure that they have cooled down sufficiently. Risk of burn 2586bz Dangerous noise level! Use hearing protection. Hearing protection 2408bz Hydraulic oil level 2158 Indication of the paving thickness. Paving thickness scale 1259532 Only use these points to lift the machine.
  • Page 51 OPERATING MANUAL Identification of the place for depositing the first-aid kit. The machine must be equipped with the first-aid kit accor- First-aid kit ding to the national regulations for first aid measures. 2427bz Lubrication points on the machine equipped with a grease nipple.

  • Page 52: Personal Protective Equipment

    Main safety precautions 2.1.11 Personal protective equipment The machine operator, technical administrators, service technicians and workers present at the workplace must use personal protecti- ve equipment during operation and maintenance of the machine: Wear work clothes (antistatic protective clothes). 0001 Wear work shoes (antistatic protective shoes).

  • Page 53: General Safety Precautions

    OPERATING MANUAL 2.1.12 General safety precautions 2.1.13 Safety precautions during machine operation Always use personal protective equipment such as work clo- thes, work shoes, a warning vest, a protective helmet, hearing Before using the machine or its equipment, make sure that no- protection and if necessary also a dust protection mask, safety body is present in the dangerous zone of the machine.

  • Page 54: Safety And Fire Precautions During The Use Of Gas Bottles

    Main safety precautions 2.1.14 Safety and fire precautions during the use of gas bottles The machine user must ensure and hand over to respective authorised workers any and all information for the safe use and Propane-butane (LPG) is an extremely flammable substance handling of gas bottles if they form part of the equipment du- and any leakage causes a high risk of fire or explosion! ring the operation of the machine always in compliance with...

  • Page 55: Safety Precautions For The Use Of Portable Fire Extinguisher

    OPERATING MANUAL 2.1.15 Safety precautions for the use of 2.1.16 Safety and fire precautions during portable fire extinguisher welding on the machine A portable fire extinguisher must comply with requirements of The machine user shall ensure that all welding works on the ma- EN 3-7+A1.

  • Page 56: Safety Precautions For Electrical And Electronic Equipment Of The Machine

    Main safety precautions 2.1.17 Safety precautions for electrical and Safety precautions electronic equipment of the machine Electrical installations and wiring must be connected properly and according to data given in this Operating Manual. • The machine is equipped with electrical wiring, components Entire electrical wiring and connection components must be and electronic equipment, the operation of which can be in- have adequate current rating within the meaning of valid regu-...

  • Page 57: Prohibited Activities

    OPERATING MANUAL 2.1.18 Prohibited activities Prohibited activities during machine control: • The machine operator must not operate the machine wit- This chapter deals with main prohibited activities during opera- hout personal protective equipment. tion, work, repairs and maintenance of the machine. •...
  • Page 58 Main safety precautions Prohibited activities during machine operation: Prohibited activities during repairs and maintenance of the machine: • Operating the machine without personal protective equip- ment. • Performing maintenance, cleaning and repairs without per- sonal protective equipment. • Operating the machine if any defects are found, if the ma- chine is not serviceable and if all safety conditions for ma- •...

  • Page 59: Preservation And Storage

    Preservation and storage 2.2.1 Storage places and storage conditions The machine can be stored under a shelter or in an open-air spa- ce. The machine can be stored in closed unheated areas or in closed air-conditioned areas as well. A machine stored for a time interval longer than 2  mon- ths must be checked regularly according to the following Before the machine is stored, it must be checked and its pre- instructions:...

  • Page 60: Preservation And Storage Of The Machine For 1-2 Months

    Preservation and storage 2.2.2 Preservation and storage of the Then it is recommended to perform the following tasks: machine for 1–2 months • repair damaged paintwork, • service lubrication points according to instructions stated in Before storing the machine, clean and wash the whole machine. the manual, Before putting the machine out of operation, start the machine •...

  • Page 61: Preservation And Storage Of The Machine For A Period Over 2 Months

    OPERATING MANUAL 2.2.3 Preservation and storage of the Then it is recommended to perform the following tasks: machine for a period over 2 months • repair damaged paintwork, • service lubrication points according to instructions stated in Before storing the machine, clean and wash the whole machine. the manual, Before putting the machine out of operation, start the machi- •...

  • Page 62: Removing Chemical Preservatives And Putting The Machine Into Operation

    Preservation and storage 2.2.4 Removing chemical preservatives and putting the machine into operation Each of the machines, on which the preservative treatment was Wash the machine only in areas with intercepting traps carried out, must be provided with instructions for removing the preservatives.

  • Page 63: Machine Disposal

    OPERATING MANUAL Machine disposal 2.3.1 Machine disposal after its service life When disposing of the machine after its lifetime expires, the machine owner must observe relevant national waste disposal regulations and environment protection regulations. Therefore we recommend you in such cases to always contact businesses specialising professionally in waste disposal.

  • Page 64: Machine Description

    Machine description D452051 F80W...

  • Page 65: Description Of Main Parts Of The Machine And Screed

    OPERATING MANUAL 2.4.1 Description of main parts of the machine and screed 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. Laying height indicator 11.
  • Page 66 Machine description 451033B D451032C F80W...
  • Page 67 OPERATING 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 68 Machine description STOP 452012 F80W...

  • Page 69: Main Dashboard

    OPERATING MANUAL 2.4.2 Main dashboard 1. Emergency switch 2. Paving width switch left 3. Paving width switch right 4. Front wheel turning angle indicator 5. Steering wheel 6. Vibration unit switch (optional equipment) 7. Screed lifting/lowering switch 8. Travel controller 9.
  • Page 70 Machine description Emergency switch (1) Screed lifting/lowering switch (7) ACZ010 Press the button to enable the machine emergency brake, ACZ021 which is indicated by lighting up the brake, emergency stop and Toggle switch with 3 positions: charging indicator lamps on the display. •...
  • Page 71 OPERATING MANUAL Ignition box (11) Selector switch of the material delivery operating mode – MAN/AUT (17) ACZ015 Switch with three positions: ACZ019 • AUT – automatic mode of material delivery • Position “0”: engine OFF. the machine moves in the operating mode, No electrical devices are powered.
  • Page 72 Machine description Fuse box (19) 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 73: Display

    OPERATING MANUAL STOP 452001 2.4.3 Display 21. Battery charging indicator lamp 22. Engine lubrication indicator lamp 23. Parking brake indicator lamp 24. Engine glowing indicator lamp 25. Machine travel forward released indicator lamp 26. Emergency stop indicator lamp 27. Machine travel backward released indicator lamp 28.
  • Page 74 Machine description Hydraulics operating mode indicator lamp Battery charging indicator lamp (21) (29) 2777 ACZ007 It indicates that the battery charging function is in order. After It indicates blocking of material feed functions, the vibration the key in the ignition box (11) is switched over to the position function and screed lowering.

  • Page 75: Foot Switch

    OPERATING MANUAL 2.4.4 Foot switch The foot switch is placed on the machine platform. Reverse travel The travel of the machine backwards is possible only in the transport mode. • Switch over the transport/operating mode switch (15) to the transport mode. •...
  • Page 76 Machine description Lowering the screed to the floating position Screed lowering using the foot switch (48) is used when trans- porting the machine or when adjusting the screed before pa- ving. During paving, the screed is supported by the asphalt mixture. The screed does not copy the unevenness of the substrate on which the machine is moving.

  • Page 77: Operation Of The Machine

    Operation of the machine 2.5.1 Turning ON/OFF the battery disconnecter Position “OFF” – Electrical wiring of the machine disconnected. Position “ON” – Electrical wiring of the machine connected. 451056 451058 F80W...

  • Page 78: Basic Equipment Of The Machine

    Operation of the machine 2.5.2 Basic equipment of the machine List of the basic equipment of the machine: • Driver's stand D451026A • Main dashboard 452015 • Engine D451036 • Hydraulic system D451037 F80W...
  • Page 79 OPERATING MANUAL • Electrical system 12 V 451039 451038 • Drive and steering D451040 • Hopper D451041 F80W...
  • Page 80 Operation of the machine • Conveyor 451042 • Augers 451043 • Screed 451044 F80W...

  • Page 81: Machine Footboard

    OPERATING MANUAL 2.5.3 Machine footboard During the operation of the machine the footboard of the ma- chine must be set in the working position (1). The footboard of the machine (1) may be set to position (2). Position (2) is intended for loading the machine with a  crane, transport of the machine on a means of transport, towing of the machine, storing and maintenance.

  • Page 82: Deposition Boxes And Safety Covers On The Machine

    Operation of the machine 2.5.4 Deposition boxes and safety covers on the machine A  deposition box situated on the right side under the cover serves for storing the Operating Manual and other documents related to the operation of the machine. The Operating Manual must always be kept in the machi- ne in an appropriate place to be always available for the driver of the machine for viewing.
  • Page 83 OPERATING MANUAL Safety cover on the machine The machine is equipped with a  safety cover of the main dashboard. This safety cover is mounted on the machine to pro- tect the equipment from damage or unauthorised use. When the machine is put out of operation or left una- ttended, the safety cover of the main dashboard must always be locked.

  • Page 84: Mounting Of Screed Reduction Plates

    Operation of the machine 2.5.5 Mounting of screed reduction plates By mounting the screed reduction plates the material paving with is changed. The paving width in the standard model of the machine is: • Minimum paving width without reduction plates 800  mm (31.5 in) •...
  • Page 85 OPERATING MANUAL Mount the paving reduction plates on the machine which is parked on parked on a flat and solid surface. When mounting reduction plates, the engine and the ba- ttery disconnecter must be switched off. Risk of burn injury when installing the screed reduction plates.

  • Page 86: Beacon

    Operation of the machine 2.5.6 Beacon The machine is delivered from the manufacturer with a beacon dismounted. Before starting the operation of the machine the beacon must be mounted on the machine. Turning on the beacon: • When the engine is started, the beacon (1) will be automa- tically turned on.

  • Page 87: Driver's Stand

    OPERATING MANUAL 2.5.7 Driver's stand To access the driver's  stand use only places intended for this purpose, the footboard and the handle. When getting on and off: • Clean your footwear before getting on the machine. • Always face the machine and pay increased attention du- ring the action.

  • Page 88: Starting The Engine

    Operation of the machine 2.5.8 Starting the engine • Before starting the engine, daily check the oil level in the engine, hydraulic tank and fuel level in the fuel tank. Check that there are no loosened, worn or missing parts on the machine.

  • Page 89: Starting The Engine Using Starting Leads From External Power Supply

    OPERATING MANUAL 2.5.9 Starting the engine using starting leads from external power supply Start-up procedure using leads from an external power supply: The starting supply voltage from the external power supply must be 12 V. Always follow the undermentioned operation sequence. 1/ Connect one end of the (+) pole of the cable to the (+) pole of the discharged battery.

  • Page 90: Travel And Reversing Of The Machine

    Operation of the machine 2.5.10 Travel and reversing of the machine STOP The machine may be operated in the transport or operating mode. The transport or operating mode are set by the switch of the transport and operating mode (15). The travel of the machine backwards is only possible in the transport mode.
  • Page 91 OPERATING MANUAL • During the travel the front wheel turning angle indicator (4) checks the turning angle. Start the engine only from the driver’s  stand! Use the alarm horn to signal the engine starting and check that nobody is endangered by starting the engine! Caution! The machine starts moving immediately in the operating mode after the forward travel control indicator (25) lights up and the travel control (8) is moved when a spe-...

  • Page 92: Stopping The Machine And Engine

    Operation of the machine 2.5.11 Stopping the machine and engine STOP Stopping the machine: • Stop and brake the machine by changing the travel contro- ller (8) to the neutral position (N). The parking brake indica- tor lamp (23) lights up. •...

  • Page 93: Machine Parking

    OPERATING MANUAL 2.5.12 Machine parking STOP Shut down the machine on a flat and solid surface where there is no potential natural hazard (e.g. landslides, flooding). • Stop and brake the machine by changing the travel contro- ller (8) to the neutral position (N). The parking brake indica- tor lamp (23) lights up.

  • Page 94: Front Wheel

    Operation of the machine 2.5.13 Front wheel The machine is fitted with a height adjustable front wheel (1). By adjusting this front wheel (1) the levelling of the machine is set as required so that the machine can pave the material in pa- rallel with the subgrade.

  • Page 95: Using And Setting The Paving Direction Indicator

    OPERATING MANUAL 2.5.14 Using and setting the paving direction indicator The machine is equipped with a paving direction indicator (3). Use: • By setting the paving direction indicator (3), the required paving direction is adhered to during the operation of the machine.

  • Page 96: Hopper

    Operation of the machine 2.5.15 Hopper The hopper is equipped with a cover (1) which prevents material from falling on the engine bonnet or to the area of the engine during loading of the material. Procedure for the hopper cover operation: •...

  • Page 97: Material Outlet

    OPERATING MANUAL 2.5.16 Material outlet It serves for controlling the flow of the material to augers. For efficient transport of material over the entire width of the screed, it is recommended to keep the augers half immersed in the asphalt mixture throughout the paving. Adjustment process: •...

  • Page 98: Conveyor

    Operation of the machine 2.5.17 Conveyor It serves for distributing the material to augers. The conveyor function is only active in working mode. Conveyor movement directions: • When distributing the material, the conveyor moves in the opposite direction of the machine travel. •...

  • Page 99: Conveyor Limit Switch

    OPERATING MANUAL 2.5.18 Conveyor limit switch If the automatic mode of the conveyor is set, it is possible to control the quantity of the delivered material to augers by se- tting the conveyor limit switch. The conveyor limit switch assembly consists of the limit switch (1) and the limit switch arm (4).

  • Page 100: Augers

    Operation of the machine 2.5.19 Augers The machine is equipped with augers which are used for mo- ving the material to the area of paving. The augers are connected with the drive of the material conve- yor. When the material conveyor is moving, both augers move as well.

  • Page 101: Operation Of The Screed

    Operation of the screed 2.6.1 Lifting and lowering the screed STOP The machine is equipped with a screed linear hydraulic motor (3). The screed linear hydraulic motor (3) is controlled by means of the screed lifting/lowering switch (7) on the main dashboard of the machine.

  • Page 102: Screed Lock

    Operation of the screed 2.6.2 Screed lock STOP The screed is locked to prevent a spontaneous fall of the screed due to possible leaks in the hydraulic system. Lock the screed with the machine parked and started, the travel controller (8) must be set in the neutral position (N). If the screed of the machine is not in use, when driving the ma- chine or transporting it by a crane, the screed tow arms must always be locked using lock pins.
  • Page 103 OPERATING MANUAL Procedure for unlocking the screed: • STOP Set the travel controller (8) to the neutral position (N). • Set the engine speed adjusting controller (10) to the maxi- mum speed. • Switch over the transport/operating mode switch (15) to the upper position.

  • Page 104: Setting The Paving Width

    Operation of the screed 2.6.3 Setting the paving width STOP The machine is equipped with a left (43) and right (44) screed extension frame for setting the paving width. The required paving width can be set using the controls (2) and (3) on the dashboard.
  • Page 105 OPERATING MANUAL Procedure for setting the required paving width on the right side of the screed: STOP • To increase the paving width on the right side, turn the pa- ving width switch (3) to the right and hold it. •...

  • Page 106: Setting The Paving Thickness

    Operation of the screed 2.6.4 Setting the paving thickness By setting the paving thickness, we can set a  variable paving thickness in the range from 5 to 100 mm (0.2 – 3.9 in). The maximum allowed difference in the paving thickness (H) on the left and right side of the machine can be 40 mm (1.6 in).

  • Page 107: Setting The Roadway Profile

    OPERATING MANUAL 2.6.5 Setting the roadway profile Setting the roadway profile defines the cross shaping of the paved layer with the purpose to drain water from the road in a crosswise direction. α The roadway profile is measured in "%" and the positive “α” and negative “ß”...

  • Page 108: Setting The End Gates

    Operation of the screed 2.6.6 Setting the end gates The screed end gates (39) prevent the paving material from ge- tting outside the paving area and creating an edge profile of the paved layer. The leading angle of the end gate directly affects the shoulder profile.

  • Page 109: Screed Vibration (Optional Equipment)

    OPERATING MANUAL 2.6.7 Screed vibration (optional equipment) STOP The function of the screed vibration serves for reducing a ma- chine travel resistance during paving and improving the surface of the paved asphalt mixture. Vibration is only active in the operating mode and machine tra- vel forward.

  • Page 110: Screed Gas Heating

    Operation of the screed 2.6.8 Screed gas heating To heat the screed with gas, liquefied propane-butane (LPG) can only be used. Stop the gas leakage. The maximum gas bottle volume which may be placed on the machine is 10 kg (22 lb). In case of gas leakage, inform relevant national authorities.
  • Page 111 OPERATING MANUAL Mounting the gas bottle on the machine: Before mounting the gas bottle on the machine, check the con- tent of the gas bottle (1) that it contains liquefied propane-bu- tane (LPG). If the contents of the gas bottle is incorrect or not known, never use the gas bottle (1)! Before mounting the gas bottle on the machine also check that the gas bottle is undamaged.
  • Page 112 Operation of the screed Procedure for gas bottle connection: • Dismount the protective cap (1) from the gas bottle shut-off valve (2). • Check that the rubber seal of the cap nut (4) of the redu- cing valve (3) is undamaged. In case of damage, replace the rubber seal of the cap nut (4) of the reducing valve (3).
  • Page 113 OPERATING MANUAL Opening the gas supply Gas is supplied via the gas bottle (9) shut-off valve (2). Before mounting the gas bottle on the machine alwa- ys check that the delivered gas bottle has a  valid revision according to the valid national regulations. Keep the safety valve (7) clean and in faultless condition.
  • Page 114 Operation of the screed Procedure for opening the gas bottle: • Slowly open the gas bottle (9) shut-off valve (2). • Check the response of the safety valve (7). • If the safety valve (7) clicks (stops the gas supply), immedia- tely close the shut-off valve (2) of the gas bottle (9) and pro- ceed according to instructions in Chapter 3.7.3.
  • Page 115 OPERATING MANUAL Procedure for setting operating pressure: • Set the gas operating pressure on the reducing valve (3) by valve (5); the gas operating pressure must be at the range of 0.6 – 0.8 bar. • Check the set values on the gas pressure gauge (6). •...
  • Page 116 Operation of the screed Procedure for gas bottle disconnection: • Close the shut-off valve (2) on the gas bottle (9). • Disconnect the gas bottle by screwing out the cap nut (4) of the reducing valve (3) on the gas bottle shut-off valve (2). •...

  • Page 117: Loading Material To The Machine

    OPERATING MANUAL 2.6.9 Loading material to the machine STOP Always load the material into the machine at the place of pa- ving, just before performing paving. The beacon of the machine must be activated when loading a material to the machine. Procedure for loading the machine •...

  • Page 118: Start Of Paving

    Operation of the screed 2.6.10 Start of paving Before paving complete the following tasks: • As needed: Adjust the front wheel. Set the paving direction indicator. Pre-set the conveyor limit switch. Pre-set material outlet. • Check that the warning beacon is connected. •...

  • Page 119: End Of Paving

    OPERATING MANUAL 2.6.11 End of paving Complete the following tasks before the end of paving: • Stop the machine as needed. • Activate the parking brake. • Turn off the screed gas heating and shut off the gas supply. • Place the screed into a ...

  • Page 120: Machine Transport

    Machine transport 2.7.1 Preparation of the machine for transport Each country has its own national transport regulations. • Familiarize yourself with these regulations and observe them. • When transporting the machine between two countries, ob- serve the stricter national transport regulations. •...

  • Page 121: Loading The Machine Using A Ramp

    OPERATING MANUAL 2.7.2 Loading the machine using a ramp Use a loading ramp to load the machine onto the transport ve- hicle. When loading the machine using a ramp, all safety regulations related to loading of the machine and complying with the nati- onal regulations in the place of loading must be adhered to.

  • Page 122: Loading The Machine With A Crane

    Machine transport 2.7.3 Loading the machine with a crane For loading with a  crane, the machine is provided with lifting lugs (1). When loading the machine, use a  crane with a  sufficient load capacity. When loading and unloading the machine or its parts, it is nece- ssary to observe relevant national regulations.

  • Page 123: Machine Transport

    OPERATING MANUAL 2.7.4 Machine transport • The machine can move on its own within the work site. When driving, observe the safety measures applicable to the working site. D451109 • The machine should be transported on a vehicle on public roads. When transporting the machine on a vehicle, observe re- gulations applicable to the given territory.

  • Page 124: Special Conditions To Use The Machine

    Special conditions to use the machine 2.8.1 Towing the machine The machine is not fitted with any system that would manually release the parking brake. If the pressure in the brake system is too low, the rear wheels will remain blocked. We recommend towing the machine only for short distances or to avoid towing completely, if possible.

  • Page 125: Climatic Conditions

    OPERATING MANUAL 2.8.2 Climatic conditions 2.8.3 Operation of the machine in dusty environment Operating the machine at low temperatures Prepare the machine for operation at low temperatures: • Replace the engine oil with the oil recommended for the range of ambient temperatures. •...
  • Page 126 Notes F80W...

  • Page 127: Maintenance Manual

    MAINTENANCE MANUAL 3 MAINTENANCE MANUAL F80W (Hatz) F80W...
  • Page 128 F80W...

  • Page 129: Safety And Other Measures During Maintenance Of The Machine

    Safety and other measures during maintenance of the machine 3.1.1 Safety precautions during machine Always start and operate the engine in a well-ventilated area. maintenance If in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system. Lubrication, maintenance and adjustment process shall be per- Do not idle the engine except as necessary.

  • Page 130: Safety And Fire Precautions During Replacement Of Operating Fluids

    Safety and other measures during maintenance of the machine 3.1.2 Safety and fire precautions during replacement of operating fluids Considering the fire danger, the flammable liquids and gas- es used on the machine are divided into the following hazard classes: •...

  • Page 131: Environmental And Hygienic Principles

    MAINTENANCE MANUAL 3.1.3 Environmental and hygienic principles 3.1.3.2 Environmental principles 3.1.3.1 Hygienic principles Some parts of the machine and operating fluids become hazar- dous wastes with dangerous properties for the environment af- ter they are put out of operation. When operating and maintaining the machines, the user and appointed workers shall observe general principles of health This category includes in particular the following: protection related to these issues according to respective nati-...

  • Page 132: Specification Of Operating Fluids

    Specification of operating fluids 3.2.1 Engine oil Viscosity diagram 2412 Engine oil has been specified as per its performance classificati- °F °C on 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) viscosi-...

  • Page 133: Fuel

    MAINTENANCE MANUAL 3.2.4 Anti-adherent 3.2.2 Fuel 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 ma- •...

  • Page 134: Liquid Gas

    Specification of operating fluids 3.2.5 Liquid gas 3.2.6 Lubricating grease 0787 The machine is equipped with a gas heating system that uses To lubricate the machine you must use a plastic grease contai- liquid gas as fuel. ning lithium according to: • Propane-butane (LPG) ISO 6743/9 CCEB 2 DIN 51 502 KP2K-30...

  • Page 135: Table Of Fluid Quantities

    Table of fluid quantities 3.3.1 Overview of fluids quantities and overview of symbols specified in maintenance plans Filling quantity Part Fluid type Brand l (gal US) Engine Engine oil according to Chapter 3.2.1. 2.2 l (0.58 gal US) 2412 Fuel tank Fuel according to Chapter 3.2.2. 5 l (1.3 gal US) Hydraulic system Hydraulic oil according to Chapter 3.2.3.

  • Page 136: Lubrication And Maintenance Chart

    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 137: Every 1000 Hours

    MAINTENANCE 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 Every 1000 hours 3.6.28 Engine oil filter cleaning 3.6.29 Hydraulic oil and hydraulic oil filter replacement* 3.6.30 Gas line hose replacement Maintenance as required...

  • Page 138: Lubrication And Service Plan

    Lubrication and service plan 3.5.1 Maintenance plan 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 country Anti-adherent solution: of machine operation D452054...

  • Page 139: Lubrication And Maintenance Operations

    Lubrication and maintenance operations Carry out lubrication and maintenance in defined intervals according to daily values on the counter of worked hours. This manual includes only basic information about the engine, STOP other information is given in the engine operation and mainte- nance manual, which is a part of the documentation supplied with the machine.

  • Page 140: Every 10 Hours At The Beginning Of Work (Daily)

    Lubrication and maintenance operations Every 10 hours at the beginning of work (daily) 3.6.1 Fuel level check The fuel tank (1) has a  capacity of 5 litres. Full tank provides approx. six hours of operation at the maximum travel speed. Regularly check the fuel tank level and add the fuel if necessary.

  • Page 141: Engine Oil Check

    MAINTENANCE MANUAL 3.6.2 Engine oil check Ensure that the machine is standing on a level and firm surface. If the engine was running, wait for about 5 minutes until the oil runs down to the engine sump. Oil check procedure: • Pull out the oil dipstick gauge (1), wipe it.

  • Page 142: Hydraulic Oil Check In The Hydraulic Tank

    Lubrication and maintenance operations 3.6.3 Hydraulic oil check in the hydraulic tank STOP Before checking the level of hydraulic oil, lower the screed all the way down and aim the front wheel straight so that hydraulic oil can flow back into the hydraulic oil tank. Ensure that the machine is standing on a level and firm surface.

  • Page 143: Driver's Stand Cleaning

    MAINTENANCE MANUAL 3.6.4 Driver's stand cleaning Clean the driver’s stand always on the machine which is parked on a flat and solid surface, with the machine engine and battery disconnecter off. Keep the driver's  stand continuously clean, dry and without snow and ice during the winter. Cleaning procedure: •...

  • Page 144: Cleaning The Hopper, Outlets And Conveyor

    Lubrication and maintenance operations 3.6.5 Cleaning the hopper, outlets and conveyor Before applying the anti-adherent solution remove gross dirt from the conveyor, material outlets and the hopper of the ma- chine. Clean the driver’s stand always on the machine which is parked on a flat and solid surface, with the machine engine and battery disconnecter off.

  • Page 145: Auger Cleaning

    MAINTENANCE MANUAL 3.6.6 Auger cleaning Before applying the anti-adherent solution remove gross dirt from the augers. Always clean the machine when it is parked on a flat and solid surface, the machine engine and the battery disconnector are off and the gas bottle is closed. Cleaning procedure: •...

  • Page 146: Test Of Burner Ignition, Flame Position Adjustment And Spark Plug Maintenance

    Lubrication and maintenance operations 3.6.7 Test of burner ignition, flame position adjustment and spark plug maintenance 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 burners ignite within a few seconds.
  • Page 147 MAINTENANCE MANUAL 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 148 Lubrication and maintenance operations 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.
  • Page 149 MAINTENANCE MANUAL Gas flame position adjustment: • Open the access to the burners. STOP • 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 glo- wing indicator lamp (24) will light up.

  • Page 150: Gas Equipment Tightness Check

    Lubrication and maintenance operations 3.6.8 Gas equipment tightness check Check the gas equipment for leakage when the machine is par- ked on a flat and solid surface and the valve (5) of the gas bottle is open. Gas equipment tightness check procedure: •...

  • Page 151: Brake Test

    MAINTENANCE MANUAL 3.6.9 Brake test 3.6.9.1 Check of the parking brake This test verifies the function of the parking brake. The operator must be present at the driver’s workplace – machine footboard – throughout the test. Perform the test on a slope with a gradi- ent of 25% (14°).

  • Page 152: Check Of The Emergency Brake

    Lubrication and maintenance operations 3.6.9.2 Check of the emergency brake This test verifies the function of the emergency brake. Due to STOP possible wear of the parking brake, the emergency brake check is to be performed with a stationary machine. During normal operation, the emergency brake button is to be used in the event of danger when the machine is running.

  • Page 153: Check Of The Service Brake

    MAINTENANCE MANUAL 3.6.9.3 Check of the service brake This test verifies the function of the service brake. After activa- ting the service brake, the hydraulic components of the machi- ne drive adjust to stop the machine. The service brake can be controlled at any time.

  • Page 154: Check Of The Tightness Of The Fuel And Hydraulic System

    Lubrication and maintenance operations 3.6.10 Check of the tightness of the fuel and hydraulic system Visually check the condition of the fuel and hydraulic system for leaking operating fluids or damage to individual system compo- nents (material degradation – ageing). Remove the identified defects. F80W...

  • Page 155: Every 10 Hours At The End Of Work (Daily)

    MAINTENANCE MANUAL Every 10 hours at the end of work (daily) 3.6.11 Fuel level check The fuel tank (1) has a  capacity of 5 litres. Full tank provides approx. six hours of operation at the maximum travel speed. Regularly check the fuel tank level and add the fuel if necessary. Refuelling procedure: •...

  • Page 156: Cleaning The Hopper, Outlets And Conveyor

    Lubrication and maintenance operations 3.6.12 Cleaning the hopper, outlets and conveyor Before applying the anti-adherent solution remove gross dirt from the conveyor, material outlets and the hopper of the ma- chine. Clean the driver’s stand always on the machine which is parked on a flat and solid surface, with the machine engine and battery disconnecter off.

  • Page 157: Auger Cleaning

    MAINTENANCE MANUAL 3.6.13 Auger cleaning Before applying the anti-adherent solution remove gross dirt from the augers. Clean the driver’s stand always on the machine which is parked on a flat and solid surface, with the machine engine and battery disconnecter off. Cleaning procedure: •...

  • Page 158: Every 50 Hours

    Lubrication and maintenance operations Every 50 hours 3.6.14 Cleaning the water separator Clean the water separator when the machine is parked on a flat and solid surface, the engine and the battery disconnector are off and the gas bottle is closed. Water separator cleaning procedure: •...

  • Page 159: Machine Lubrication

    MAINTENANCE MANUAL 3.6.15 Machine lubrication Lubricate the machine when it is parked on a flat and solid sur- face, the engine and the battery disconnector are off and the gas bottle is closed. Use the prescribed lubricants according to Chapter 3.2.6 for lub- ricating the machine.
  • Page 160 Lubrication and maintenance operations Procedure for lubrication of the paving width setting me- chanism: • The procedure is identical for the left and right side of the screed. • Set the maximum paving width on both screed sides. • Remove lubricating grease residues and dust from the screed extension guide (1).
  • Page 161 MAINTENANCE MANUAL Conveyor chain and auger chain lubrication procedure: Conveyor chain lubrication procedure: • Apply the lubricating grease on chains (2) and (3) in point (1) with a brush. Auger chain lubrication procedure: • Remove the cover (4). • Apply the lubricating grease on chains (5) with a brush. •...

  • Page 162: Every 100 Hours Of Operation

    Lubrication and maintenance operations Every 100 hours of operation 3.6.16 Fuel system tightness check Fuel system tightness check procedure: • Open the left material hopper side cover (1). • Open the engine bonnet (2). • Dismount the inlet air filter cap (3) and remove the inlet air filter cover (4).

  • Page 163: Rear Wheel Fastening Check

    MAINTENANCE MANUAL 3.6.17 Rear wheel fastening check • The procedure is identical for the left and right side of the machine. Rear wheel fastening check procedure (the machine has one wheel on the left and right side): • Check tightening of all bolts (1) on the rear wheels (2). •...

  • Page 164: Conveyor Chain Tensioning

    Lubrication and maintenance operations 3.6.18 Conveyor chain tensioning Calculate the sag of the conveyor chain by measuring the di- stance between the ground and the left conveyor chain (1) or the right conveyor chain (2), always in the central part of the chain.

  • Page 165: Every 250 Hours Of Operation

    MAINTENANCE MANUAL Every 250 hours of operation 3.6.19 Engine oil replacement Change the engine oil when the machine is parked on a flat and solid surface, the engine and the battery disconnector are off and the gas bottle is closed. Engine oil replacement procedure: •...

  • Page 166: Engine Air Intake Check

    Lubrication and maintenance operations 3.6.20 Engine air intake check Check the engine air intake always on the machine which is par- ked on a flat and solid surface, with the machine engine and ba- ttery disconnecter off. Engine air intake check procedure: •...

  • Page 167: Hydraulic Oil Cooler Cleaning

    MAINTENANCE MANUAL 3.6.21 Hydraulic oil cooler cleaning Perform cleaning of the hydraulic oil cooler when the machine is parked on a flat and solid surface with the engine and battery disconnecter off. Check the hydraulic oil cooler fins (1) that they are not dirty or clogged.

  • Page 168: Hydraulic Circuit Tightness Check

    Lubrication and maintenance operations 3.6.22 Hydraulic circuit tightness check Check the hydraulic circuit for leakage when the machine is parked on a flat and solid surface, the engine and the battery disconnector are off and the gas bottle is closed. Hydraulic circuit tightness check procedure: •...

  • Page 169: Battery Check

    MAINTENANCE MANUAL 3.6.23 Battery check Perform battery check when the machine is parked on a flat and solid surface with the engine and battery disconnecter off. The machine is delivered from the manufacturer with a mainte- nance-free battery. If a maintenance-free battery is installed in the machine, it is not necessary to check the electrolyte level and refill the electrolyte for the entire service life of the battery.
  • Page 170 Lubrication and maintenance operations Battery charging procedure: • Open the left material hopper side cover (1). • Clean the battery surface. • Remove the battery from the machine. • When disconnecting the battery, first disconnect the cable of the (-) pole. •...

  • Page 171: Checking The Conveyor Drive Chain Tension

    MAINTENANCE MANUAL 3.6.24 Checking the conveyor drive chain tension Make sure the battery disconnecter is switched off before checking the chain on the machine. Use a suitable tool to check the chain tension. The chain sag should correspond to approximately two grooves on the scale of the cover plate.

  • Page 172: Every 500 Hours Of Operation, But At Least Once A Year

    Lubrication and maintenance operations Every 500 hours of operation, but at least once a year 3.6.25 Replacement of fuel filters Perform the fuel filter replacement when the machine is parked on a  flat and solid surface with the engine and battery disco- nnecter off.
  • Page 173 MAINTENANCE MANUAL Replacement of the intake fuel filter: • Remove the intake fuel filter (1) from the fuel tank. • Remove the clamp (2). • Remove the filter (1). • Install a new filter. • Mount the clamp (2). Replace the fuel filter when the machine is parked on a flat and solid surface, the engine and the battery disco- 452065 nnector are off and the gas bottle is closed.

  • Page 174: Air Filter Replacement

    Lubrication and maintenance operations 3.6.26 Air filter replacement Perform air filter replacement when the machine is parked on a flat and solid surface with the engine and battery disconnecter off. Air filter replacement procedure: • Open the left material hopper side cover (1). •...

  • Page 175: Front And Rear Wheel Condition Check

    MAINTENANCE MANUAL 3.6.27 Front and rear wheel condition check Perform front and rear wheel condition check when the machi- ne is parked on a flat and solid surface with the engine and ba- ttery disconnecter off. Front and rear wheel condition check procedure: •...

  • Page 176: Every 1000 Hours

    Lubrication and maintenance operations Every 1000 hours 3.6.28 Engine oil filter cleaning Clean the engine oil filter when the machine is parked on a flat and solid surface, the engine and the battery disconnector are off and the gas bottle is closed. Engine oil draining and engine oil filter removal procedure: •...
  • Page 177 MAINTENANCE MANUAL Procedure for oil volume check in the engine: • Start the engine. • Leave the engine to idle for at least for 5 minutes. • Turn off the engine. • Wait approximately for 5 minutes before oil flows to the sump and check the level again.

  • Page 178: Hydraulic Oil And Hydraulic Oil Filter Replacement

    Lubrication and maintenance operations 3.6.29 Hydraulic oil and hydraulic oil filter replacement Change the hydraulic oil when the machine is parked on a flat and solid surface, the engine and the battery disconnector are off and the gas bottle is closed. Hydraulic oil change and ventilation filter replacement pro- cedure: •...
  • Page 179 MAINTENANCE MANUAL Hydraulic oil filter element replacement: • Remove filter cap (1). • Unlock the filter element (2). • Pull out the filter element from the filter housing (3). • Insert a new filter element (4). • Turn the filter element clockwise up to the stop (4.1). •...

  • Page 180: Gas Line Hose Replacement

    Lubrication and maintenance operations 3.6.30 Gas line hose replacement Perform gas line hose replacement when the machine is parked on a flat and solid surface with the engine and battery disconne- cter off and with the closed gas bottle shut-off valve. Have the gas line hose replacement performed by an authorised service plant or qualified personnel.

  • Page 181: Maintenance As Required

    MAINTENANCE MANUAL Maintenance as required 3.6.31 Battery replacement Perform battery replacement when the machine is parked on a flat and solid surface with the engine and battery disconnecter off. Battery replacement procedure: • Open the left material hopper side cover (1). •...

  • Page 182: Charging Of The Battery

    Lubrication and maintenance operations 3.6.32 Charging of the battery • Remove the battery from the machine to charge. • Only use chargers with an appropriate rated voltage. Check Use rubber gloves and eye protection devices when that the charger is strong enough to charge the battery not handling the battery.

  • Page 183: Screw Connections Tightness Check

    MAINTENANCE MANUAL 3.6.33 Screw connections tightness check • Check regularly whether the screwed joints are not loosened. • Use the torque spanner for tightening. TIGHTENING TORQUE VALUES TIGHTENING TORQUE VALUES For the screws 10.9 For the screws 10.9 For the screws 8.8 (8G) (10K) For the screws 8.8 (8G) (10K)
  • Page 184 Lubrication and maintenance operations Table of tightening torque values for necks with tightening Table of tightening torque values for plugs with flat packing edge, or with flat packing Tightening torques of the neck Tightening torques of the plug lb ft lb ft G 1/8 G 1/8...

  • Page 185: Troubleshooting

    Troubleshooting MAINTENANCE MANUAL 3.7.1 Troubleshooting The defects are usually caused by incorrect operation of the machine. Therefore in case of any defect read carefully in- structions given in the operation and maintenance manual for your machine and engine. If you cannot identify a cause of the defect, contact and authorised service plant or qualified personnel.

  • Page 186: Troubleshooting The Electrical System

    Troubleshooting Fault Possible causes Corrective action Decreased machine performance • Leak of the solenoid valve • Have the components repaired • Leak of the linear hydraulic motor • Have the linear hydraulic motor re- paired • Leak of the drive pump or the opera- •...

  • Page 187: List Of Error Codes Displayed On The Display

    MAINTENANCE MANUAL 3.7.6 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 – check wiring (X43, RD 143, WH 229) brake pressure sensor short circuit to ground detected –...
  • Page 188 Troubleshooting Code F Short description Causes and troubleshooting screed enable valve short circuit to ground or battery or no connection detected – check wiring and coil (X62, Y9, WH 260, BN 326) screed up valve short circuit to ground or battery or no connection detected – check wiring and coil (X63, Y10, WH 261, BN 327) extension left out valve short circuit to ground or battery or no connection detected –...
  • Page 189 MAINTENANCE MANUAL Code F Short description Causes and troubleshooting ignition 2 misfire ignition box 2 indicates misfire – check gas flow and burner ignition 2 (X74, X77, I2) ignition 3 misfire ignition box 3 indicates misfire – check gas flow and burner ignition 3 (X75, X78, I3) heating output short circuit to ground or battery or no connection detected –...

  • Page 190: Appendices

    Appendices Appendices 3.8.1 Machine wiring diagram Legend: A1 Diesel engine S6 Brake pressure switch A2 BODAS RC control unit S7 Travel switch A3 Display unit S8 Foot switch A4 Travel control lever S9 Horn button A5 Diagnostic socket S10 Left smoothing screed extension switch A6 Screed heating unit 1 (left) S11 Right smoothing screed extension switch A7 Screed heating unit 2 (middle)
  • Page 191 MAINTENANCE 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 X6: 7 X61: 1 X61:12 X1.2:5 X1.2:6 X61: 2 X1.2:2 X1.1:5 X17: 1 49 Fuel valve - X6: 14 50 Fuel valve + 18 Senzor GND 35 Oil temp.
  • Page 192 Appendices Machine wiring diagram Legend: A1 Diesel engine S6 Brake pressure switch A2 BODAS RC control unit S7 Travel switch A3 Display unit S8 Foot switch A4 Travel control lever S9 Horn button A5 Diagnostic socket S10 Left smoothing screed extension switch A6 Screed heating unit 1 (left) S11 Right smoothing screed extension switch A7 Screed heating unit 2 (middle)
  • Page 193 MAINTENANCE 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 194 Appendices Machine wiring diagram Legend: A1 Diesel engine S6 Brake pressure switch A2 BODAS RC control unit S7 Travel switch A3 Display unit S8 Foot switch A4 Travel control lever S9 Horn button A5 Diagnostic socket S10 Left smoothing screed extension switch A6 Screed heating unit 1 (left) S11 Right smoothing screed extension switch A7 Screed heating unit 2 (middle)
  • Page 195 MAINTENANCE 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 40419C_3en F80W...

  • Page 196: Machine Hydraulic System Diagram

    Appendices 3.8.2 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 197 MAINTENANCE MANUAL 451190 F80W...

  • Page 198: Measuring Points Of The Hydraulic Circuit

    Appendices 3.8.2.1 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 199: Screed Gas Heating System Diagram

    MAINTENANCE MANUAL 12 V 451900 3.8.3 Screed gas heating 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...

  • Page 200: Table Of Spare Parts For Regular Maintenance

    Appendices 3.8.4 Table of spare parts for regular maintenance Chapter Spare part 3.6.25 Fuel filter 3.6.26 Air filter 3.6.27 Front wheels 3.6.27 Rear wheels 3.6.28 Engine oil filter and O-Ring 3.6.28 O-Ring 3.6.29 Set of hydraulic oil filters 3.8.5 Content of the filter set after 500 hours (4812088753) Chapter Spare part Number of parts...
  • Page 201 MAINTENANCE MANUAL Notes F80W...
  • Page 202 Appendices Notes F80W...
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