Atlas Copco Dynapac F1000W T4i Troubleshooting guide

F1000W T4i
Edit.2 Mar.2016 D717410129(A4);4812247566(A5)
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OPERATION & MAINTENANCE
Paver Finisher
EN Keep for later use in document compartment
Valid for:

www.atlascopco.com

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Table of contents
VPreface ..................................................................................... 1
1General safety instructions .................................................................................................. 3
1.1 Acts, directives, accident prevention regulations ................................................................. 3
1.2 Warning instructions ............................................................................................................ 3
1.3 Prohibitive signs .................................................................................................................. 6
1.4 Protective gear .................................................................................................................... 7
1.5 Environmental protection ..................................................................................................... 8
1.6 Fire prevention ..................................................................................................................... 8
1.7 Further instructions .............................................................................................................. 9
ACorrect use and application ................................................... 1
BVehicle description ................................................................. 1
1Application ........................................................................................................................... 1
2Description of assemblies and functions ............................................................................. 2
2.1 Vehicle ................................................................................................................................. 3
Construction ...................................................................................................................3
3Danger Zones ...................................................................................................................... 6
4Technical data, standard configuration ................................................................................ 7
4.1 Dimensions (all dimensions in inches) ................................................................................. 7
4.2 Allowed angle of rise and slope ........................................................................................... 8
4.3 Permissible approach angle ................................................................................................ 8
4.4 Turning circle ....................................................................................................................... 8
4.5 Weights, F1000W ................................................................................................................9
4.6 Performance data ................................................................................................................ 9
4.7 Traction drive/chassis ........................................................................................................ 10
4.8 Engine ............................................................................................................................... 10
4.9 Hydraulic systemOperator stations .................................................................................... 10
4.10 Electrical system ................................................................................................................ 10
4.11 Operator stations ............................................................................................................... 11
4.12 Material compartment (hopper) ......................................................................................... 11
4.13 Conveyor ........................................................................................................................... 11
4.14 Augerr ................................................................................................................................ 11
4.15 Permissible temperature ranges ........................................................................................ 11
5Location of instruction labels and identification plates ....................................................... 12
6EN standards ..................................................................................................................... 17
6.1 Continuous sound pressure level on the F1000W Wheeled Paver, Cummins
QSB-6.70 Tier III Engine. .................................................................................................. 17
6.2 Operating conditions during measurement ........................................................................ 17
6.3 Measuring point configuration ........................................................................................... 18
C1.1 Transport ................................................................................. 1
1Safety regulations for transportation .................................................................................... 1
2Transportation on low-bed trailers ....................................................................................... 3
2.1 Preparations ........................................................................................................................ 3
2.2 Driving onto the low-bed trailer ............................................................................................ 6
2.3 Secure the paver finisher to the low-bed trailer: .................................................................. 6
2.4 After transportation .............................................................................................................. 7

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3Transportation ..................................................................................................................... 8
3.1 Preparations ........................................................................................................................ 8
3.2 Driving mode ..................................................................................................................... 11
4Loading by crane ...............................................................................................................13
5Towing ............................................................................................................................... 15
6Safely parking the vehicle .................................................................................................. 16
D1.1 Operation ................................................................................. 1
1Safety regulations ................................................................................................................ 1
2Controls ............................................................................................................................... 2
2.1 Operating panel ................................................................................................................... 2
3Auxiliary functions .............................................................................................................. 25
4Left / right remote controls and handsets .......................................................................... 27
Left / right remote control .............................................................................................. 28
Left / right handset ........................................................................................................ 37
D2.0 Operation ................................................................................. 1
1Operation of the graphical terminal ..................................................................................... 1
1.1 Navigation using Soft Keys .................................................................................................. 2
Brightness/Contrast
Adjustment .....................................................................................................................3
Main Menu - Start Menu ................................................................................................. 3
Main Menu - Basic Setup ............................................................................................... 4
Main Menu - Basic Setup
-Time / Date .................................................................................................................... 5
Main Menu - Basic Setup
-Language ......................................................................................................................5
Main Menu - Basic Setup
-Units .............................................................................................................................. 6
Main Menu - Diagnostics ................................................................................................ 7
Main Menu - Diagnostics
-System Info ...................................................................................................................8
Main Menu - Diagnostics
-Fault Log ....................................................................................................................... 8
Main Menu - Diagnostics
-Fault Log
Active and Previous Faults ............................................................................................. 9
Main Menu - Diagnostics
-Fault Pop-Up Alarms ................................................................................................... 10
Main Menu - Diagnostics
-Device List ...................................................................................................................11
Main Menu - Diagnostics
-Quick Data .................................................................................................................. 12
Start Display ................................................................................................................. 13
Display 01 .....................................................................................................................14
Display menu ................................................................................................................ 14
Display 02 .....................................................................................................................14
Display menu ................................................................................................................ 14
Active Faults Display .................................................................................................... 15
Fault Sources and Codes ............................................................................................. 15
Warnings Display .......................................................................................................... 17

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1.2 Engine Error messages ..................................................................................................... 18
1.3 FMI-codes .......................................................................................................................... 23
D3.0 Operation ................................................................................. 1
1Operating elements on the paver ........................................................................................ 1
Operator’s platform ........................................................................................................ 1
Seat console ...................................................................................................................1
Operating panel .............................................................................................................. 1
Driver's seat .................................................................................................................... 2
Batteries ........................................................................................................................ 2
Battery main switch ........................................................................................................ 3
Transport safeguards for the hopper ............................................................................. 4
Mechanical screed transport safeguard (to the left and the right beneath
the driver’s seat) .............................................................................................................4
Paving thickness indicator ............................................................................................. 5
Release Agent System ................................................................................................... 6
On/Off switch of working lights (1) .................................................................................. 7
On/Off switch hazard flasher (2): .................................................................................... 7
Warning Beacon ............................................................................................................. 7
Conveyor limit sensors ................................................................................................... 8
Ultrasonic auger limit sensors (left and right) ................................................................. 8
Sockets 24V ................................................................................................................... 8
D4.0 Operation ................................................................................. 1
1Preparation of operation ...................................................................................................... 1
Required equipment and tools ........................................................................................ 1
Before starting work
(in the morning or when starting paving) ........................................................................ 2
Checklist for the machine operator ................................................................................. 2
1.1 Starting the paver ................................................................................................................ 5
Before starting the paver ................................................................................................ 5
“Normal” starting ............................................................................................................. 5
Jump starting ..................................................................................................................7
After starting ................................................................................................................... 9
1.2 Transport Operation .......................................................................................................... 11
Lifting and securing the screed ..................................................................................... 11
Driving and stopping the paver ..................................................................................... 11
Switching off and securing the paver ............................................................................ 11
1.3 Preparations for paving ..................................................................................................... 12
Releasing agent ........................................................................................................... 12
Screed heater ............................................................................................................... 12
Direction marks ............................................................................................................. 12
Loading/distributing material ......................................................................................... 14
1.4 Starting for paving ............................................................................................................. 16
1.5 Check during paving .......................................................................................................... 17
Paver function .............................................................................................................. 17
Quality of the layer ....................................................................................................... 17
1.6 Interrupting/terminating operation ...................................................................................... 19
During breaks (i.e. the material supply truck is late) ..................................................... 19
During extended interruptions
(i.e. lunch break) ........................................................................................................... 19

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When work is finished ................................................................................................... 21
2Malfunctions ...................................................................................................................... 22
2.1 Problems during paving ..................................................................................................... 22
2.2 Malfunctions on the paver or screed ................................................................................. 24
E1.0 Set-up and modification ......................................................... 1
1Special notes on safety ....................................................................................................... 1
2Auger ................................................................................................................................... 2
2.1 Height adjustment ................................................................................................................ 2
2.2 Auger crossbeam - hydraulic height adjustment .................................................................. 2
2.3 Auger extension ................................................................................................................... 3
2.4 Mounting extension parts .................................................................................................... 4
2.5 Mounting support tube extensions ....................................................................................... 5
2.6 Installing tunnel plates ......................................................................................................... 6
2.7 Installing additional braces .................................................................................................. 7
3Screed ................................................................................................................................. 8
4Electrical connections .......................................................................................................... 8
4.1 Remotes from screed to paver ............................................................................................ 8
4.2 Right hand conveyor sensor control .................................................................................... 8
4.3 Right hand auger sensor control ......................................................................................... 8
4.4 Left hand conveyor sensor control ...................................................................................... 9
4.5 Left hand auger sensor control ............................................................................................ 9
4.6 Auger Chart ....................................................................................................................... 10
F1.0 Maintenance ............................................................................ 1
1Notes regarding safety ........................................................................................................ 1
F2.1 Maintenance Overview ........................................................... 1
1Maintenance overview ......................................................................................................... 1
F3.0 Maintenance - Conveyor ........................................................ 1
1Maintenance - Conveyor ..................................................................................................... 1
1.1 Maintenance intervals ..........................................................................................................2
1.2 Points of maintenance ......................................................................................................... 3
Chain tension of the conveyor (1) ................................................................................... 3
Conveyor tensioning sprocket bearings (2) .................................................................... 5
Conveyor bearing (3) ...................................................................................................... 5
Conveyor drive - (5) drive chains .................................................................................... 6
Conveyor drive - (6) planetary drive (left/right) .............................................................. 7
Conveyor chain guards / conveyor plates (7) ................................................................. 8
F4.0 Maintenance - Auger ............................................................... 1
1Maintenance - Auger sub-unit I ........................................................................................... 1
1.1 Maintenance intervals ..........................................................................................................2
1.2 Points of maintenance ......................................................................................................... 3
Auger - outer bearing (1) ............................................................................................... 3
Auger middle bearing (2) ................................................................................................ 3
Auger - drive gear neck bearing (3) ................................................................................ 4

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Auger bevel gear (on the RH and LH sides) (4) ............................................................. 5
Auger blade (5) ............................................................................................................... 6
F5.0 Maintenance - Engine ............................................................. 1
1Maintenance - engine sub-unit ............................................................................................ 1
1.1 Maintenance intervals ..........................................................................................................2
1.2 Points of maintenance ......................................................................................................... 4
Engine fuel tank (1) ....................................................................................................... 4
Engine lube-oil system (2) ............................................................................................. 5
Engine fuel system (3) ................................................................................................... 7
Engine air cleaner (4) ..................................................................................................... 9
Engine Coolant system (5) ........................................................................................... 11
Engine drive belt (6) ..................................................................................................... 13
F6.0 Maintenance - Hydraulic System ...........................................1
1Maintenance - hydraulic system .......................................................................................... 1
1.1 Maintenance intervals ..........................................................................................................2
1.2 Hydraulic System ................................................................................................................. 3
1.3 Points of maintenance ......................................................................................................... 4
Hydraulic oil tank (1) ....................................................................................................... 4
Suction/return flow hydraulic filter (2) ............................................................................. 6
Venting the filter: ............................................................................................................7
High pressure filter (3) .................................................................................................... 8
Pump distribution gear (4) .............................................................................................. 9
Hydraulic hoses (5) ....................................................................................................... 11
F7.1 Maintenance - Travel Drive, Steering .................................... 1
1Maintenance - travel drive, steering .................................................................................... 1
1.1 Maintenance intervals ..........................................................................................................2
1.2 Points of maintenance ......................................................................................................... 3
Wheel mounting nuts (1) ................................................................................................ 3
Rear wheels ................................................................................................................... 3
Front wheels (with front wheel drive) ............................................................................. 3
Planetary gear (2) ........................................................................................................... 4
Air pressure (driving wheels) (3) ..................................................................................... 6
Places of lubrication (4) .................................................................................................. 7
F8.1 Maintenance - Electronic System .......................................... 1
1Maintenance - Electronic system ......................................................................................... 1
1.1 Maintenance intervals ..........................................................................................................2
1.2 Points of maintenance ......................................................................................................... 3
Batteries (1) .................................................................................................................... 3
Electric fuses / relays (3) ................................................................................................ 4
Fuses in terminal box (B) ............................................................................................... 5
Relays in terminal box (C) ............................................................................................. 7
F9.0 Maintenance - Lubricating Points ......................................... 1
1Maintenance - Lubricating points ......................................................................................... 1

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1.1 Maintenance intervals ..........................................................................................................2
1.2 Points of maintenance ......................................................................................................... 3
Bearing points (1) ........................................................................................................... 3
F10.0 Checks, Decommissioning .................................................... 1
1Tests, check-up, cleaning, stopping .................................................................................... 1
1.1 Maintenance intervals ..........................................................................................................2
2General observation ............................................................................................................3
3Check performed by a specialist ......................................................................................... 3
4Cleaning .............................................................................................................................. 4
5Preservation for storage of paver ........................................................................................ 5
5.1 Downtime up to 6 months .................................................................................................... 5
5.2 Downtime between 6 months and 1 year. ........................................................................... 5
5.3 Re-commissioning: ..............................................................................................................5
F11.0 Lubricants and Operating Substances ................................ 1
1Lubricants and operating substances ................................................................................. 1
1.1 Capacities ............................................................................................................................ 2
6 Environmental protection, disposal .....................................................................................6
6.1 Environmental protection ........................................................................................................6
6.2 Disposal .................................................................................................................................6

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VPreface
Safe operation of the machine requires specific knowledge that is in these operating
instructions. The information is provided in a concise, clearly structured form. The in-
dividual chapters are arranged in alphabetical order and every chapter starts with
page 1. The individual pages are identified by the chapter letter and the page number.
Example: Page B 2 is the second page of chapter B.
These operating instructions cover various machine options. Make sure that during
operation and maintenance work the description appropriate to the machine option is
used.
Safety instructions and important notes are identified by the following:
Danger is used ot indicate the presence of a hazard which will cause severe per-
sonal injury, death, or substantial property damage if the warning is ignored.
Warning is used to indicate the presence of a hazard which can cause severe personal injury, death, or
extensive property damage if the warning is ignored.
Caution is used to indicate the presence of a hazard which will or can cause minor
personel injury or property damage if the warning is ignored.
Notifies people of installation, operation or maintenance information which is impor-
tant but not hazard-related. Hazard warnings should never be included under the No-
tice indicator.
NOTE:
Note is used for supplementary information not directly effecting safety or damage to
the equipment. Note can also refer to special information on the efficient use of the
equipment.
In the interest of continued development, the manufacturer reserves the right to make
changes to the machine (which will not, however, change the essential features of the
type of machine described) without updating the present operating instructions at the
same time.

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Dynapac (China) Compaction & Paving Equipment Co., Ltd.
No.38, Quanwang Road,
Wuqing High Tech Industrial Park,301700,
Tianjin, China
www.dynapac.com

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1 General safety instructions
1.1 Acts, directives, accident prevention regulations
The locally applicable acts, directives and accident prevention regulations shall be observed, even if the
attention is not specifically directed to these.
The operator himself shall be responsible for the observation and performance of the related regulations
and actions!
The following alerts, prohibitions and instructions refer to the risks to which people, machinery and en-
vironment are exposed.
Ignoring these instructions, bans and commands may lead to fatal injuries!
Furthermore, the Dynapac publication "Directives for the correct and specified application of pavers"
shall also be observed.
1.2 Warning instructions
A paving machine has many components and implements that are controlled by a hydraulic system, ei-
ther directly or indirectly. Before working on or inspecting any part of a paving machine, it is important
that the individual knows how the components move and are controlled by the hydraulic system compo-
nents including the respective control circuits.
Before working on or inspecting any component, it must be physically constrained from any movement
that chould cause injury to the worker. The worker must be alert to not placing any part of his/her body
where movement of a component could cause injury, unless that component is physically constrained
from movement, if the hydraulic system fails, is disconnected, or is asignaled to cause movement.
It must also be recognized that there are occasions where component and or vehicle movement may
react to the release of potential energy. Where applicable it must be confirmed that all measures are
employed to ensure that any and all sources of potential energy are released and/ or physically re-
strained.
It is also the responsibility of those involved to insure that all local, state and federal safety regulations
are followed, prior to, and during any work or inspection.

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Warning: areas of hazard or danger!
Not observing the warning instructions may lead to injuries or death!
Warning: rotating parts!
Rotating parts or transport parts can cause severe injury or death!
Perform each operation only with equipment switched off!
Attention: electric voltage!
All maintenance and repair work on the screed's electrical system
must always be carried out by an electrician!
Attention: suspended load!
Never stand under suspended loads!
Warning: risk of crushing!
Operation of certain parts or functions and moving the machine can
produce a risk of crushing.
Always make sure that no one is in the areas exposed to risk!
Caution: risk of hand injury!
Caution: hot surfaces or hot liquids!

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Warning, risk of falling off!
Falling can cause severe injury or death!
Caution: hazardous batteries!
Combustible gas can cause severe burns, blindness or death!
Keep sparks and open flame away from batteries.
Caution: materials harmful to health and irritating substances!
Caution: flammable materials!
Caution: gas bottles!

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1.3 Prohibitive signs
It is prohibited to open / step on / reach into / perform / adjust
during operation or when the paver engine is running!
Do not start the engine/drive!
Maintenance and repair can be carried out only with the Diesel en-
gine turned off!
Do not spray with water!
Do not extinguish with water!
Unskilled maintenance is prohibited!
Maintenance can be performed by skilled professionals only!
Contact the Dynapac service for maintenance assistance!
Danger of fire: do not use open flame and no smoking!
Do not turn on!

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1.4 Protective gear
The applicable local regulations may define the use of different protective gear!
Observe these specifications!
Protect your eyes with goggles!
Wear appropriate head protection!
Protect your hearing with appropriate ear mufflers!
Protect your feet with safety footwear!
Always wear tight, conforming working coveralls!
Wear visibility vest for good visibility!
In case of polluted air, wear respiratory mask!

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1.5 Environmental protection
The locally applicable acts, directives and waste disposal regulations shall be ob-
served, even if the attention is not specifically directed to these.
During cleaning, maintenance and repair operations, pollutants such as:
- lubricants (oils, grease)
- hydraulic oil
-gasoil
- coolant
- detergents
may not enter the soil or the sewer system!
These materials shall be collected, stored, transported in the correct
containers until professional disposal!
Material harmful for the environment!
1.6 Fire prevention
The applicable local regulations may specify that appropriate fire extinguishers be
mounted!
Observe these specifications!
Fire fighting device
(optional equipment)

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1.7 Further instructions
Observe the manufacturer's and other instructions!
(i.e. the maintenance instructions from the engine manufacturer)
Indicates a bottled gas heated design!
indicates an electrically heated design!

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A Correct use and application
The “Guidelines for the Correct Use and Application of Paver” compiled by Dynapac
are included in the scope of delivery for the present machine. The guidelines are part
of the present operating instructions and must always be followed. Federal, state and
local regulations are fully applicable.
The road construction machine described in these operating instructions is a paver
that is suited for laying mixed materials, roll-down concrete or lean-mixed concrete,
track-laying ballast and unbound mineral aggregates for paving foundations.
This machine shall be used, operated and maintained for the purpose of the intended
work as included in the operation manual. Any other use is regarded as improper use
and can cause injury to persons or damage to the paver or other equipment or prop-
erty.
Any use going beyond the range of applications described above is regarded as im-
proper use and is expressly forbidden! Especially in those cases where the paver is
to be operated on inclines or where it is to be used for special purposes (i.e. construc-
tion of dumps, dams), it is absolutely necessary to contact the manufacturer.
Duties of the user: A “user” within the meaning of the present operating instructions
is defined as any natural or legal person who either uses the paver himself, or on
whose behalf it is used. In special cases (i.e. leasing or renting), the user is consid-
ered the person who, in accordance with existing contractual agreements between
the owner and the user of the paver , is charged with the observation of the operating
duties.
The user must ensure that the paver is only used in the stipulated manner and that
all danger to life and limb of the operator, or third parties, is avoided. In addition to
this, it must be ensured that the relevant accident prevention regulations and other
safety-related provisions as well as the operating, servicing and maintenance guide-
lines are observed. The user must also ensure that all persons operating the equip-
ment have read and understood the present operating instructions.
Mounting attachments: The paver must only be operated in conjunction with
screeds that have been approved by the manufacturer. Mounting or installation of any
attachments that will interfere with or supplement the functions of the paver is permit-
ted only after written approval by the manufacturer has been obtained. If necessary,
the approval of local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.