Dynapac F1200C Troubleshooting guide

OPERATION & MAINTENANCE
Paver Finisher
Dynapac
F1200C / F1200CS
Typ 456 / 457
Keep for later use in document compartment
4812023636 (A5)02-0416
Valid for:
_________________ - _________________
_________________ - _________________

www.dynapac.com

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Table of contents
V Preface ..................................................................................... 1
1 General safety instructions ........................................................................ 2
1.1 Laws, guidelines, accident prevention regulations ..................................... 2
1.2 Safety signs, signal words ......................................................................... 3
"Danger"! ............................................................................................... 3
"Warning" ! ............................................................................................. 3
"Caution" ! .............................................................................................. 3
"Note" ! ................................................................................................... 3
1.3 Other supplementary information ............................................................... 3
1.4 Warnings .................................................................................................... 4
1.5 Prohibitive symbols .................................................................................... 6
1.6 Protective equipment ................................................................................. 7
1.7 Environmental protection ........................................................................... 8
1.8 Fire prevention ........................................................................................... 8
1.9 Additional information ................................................................................ 9
2 CE identification and Declaration of Conformity ...................................... 10
3 Guarantee conditions ............................................................................... 10
4 Residual risks ........................................................................................... 11
5 Sensibly predictable incorrect usage ....................................................... 12
A Correct use and application ................................................... 1
B Vehicle description ................................................................. 1
1 Application ................................................................................................. 1
2 Description of assemblies and functions .................................................... 2
2.1 Vehicle ....................................................................................................... 3
Construction ........................................................................................... 3
3 Danger zones ............................................................................................. 6
4 Safety devices ............................................................................................ 7
5 Technical data, standard configuration ...................................................... 9
5.1 Dimensions (all dimensions in mm) ........................................................... 9
5.2 Permissible approach angle ..................................................................... 10
5.3 Weights F1200C (all weights in t) ............................................................ 11
5.4 Weights F1200CS (all weights in t) .......................................................... 11
5.5 Performance data F1200C ....................................................................... 12
5.6 Performance data F1200CS .................................................................... 12
5.7 Travel drive/traction unit ........................................................................... 13
5.8 Engine EU 3A / Tier 3 - F1200C (o) ......................................................... 13
5.9 Engine EU 3B / Tier 4f - F1200C (t) ......................................................... 13
5.10 Engine EU 3A / Tier 3 - F1200CS (o) ...................................................... 13
5.11 Engine EU 3B / Tier 4f - F1200CS (t) ...................................................... 13
5.12 Material compartment (hopper) ................................................................ 14
5.13 Material transfer ....................................................................................... 14
5.14 Material distribution .................................................................................. 14
5.15 Electrical system ...................................................................................... 14

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5.16 Permissible temperature ranges ..............................................................14
6 Identification points ...................................................................................15
6.1 Warning signs ...........................................................................................18
6.2 Information signs ......................................................................................20
6.3 CE marking ...............................................................................................22
6.4 Instructive symbols, prohibitive symbols, warning symbols .....................23
6.5 Further warnings and operating instructions ............................................23
6.6 Identification label for the paver finisher (41) ........................................24
6.7 Explanation of 17PIN serial number .........................................................25
7 EN standards ............................................................................................26
7.1 Continuous sound pressure level .............................................................26
7.2 Operating conditions during measurement ..............................................26
7.3 Measuring point configuration ..................................................................26
7.4 Vibration acting on the entire body ...........................................................27
7.5 Vibrations acting on hands and arms .......................................................27
7.6 Electromagnetic compatibility (EMC) .......................................................27
C10.12 Transportation ........................................................................1
1 Safety regulations for transportation ..........................................................1
2 Transportation on low-bed trailers ..............................................................2
2.1 Preparations ...............................................................................................2
3 Securing the load .......................................................................................4
3.1 Prepare the low-bed trailer .........................................................................4
3.2 Driving onto the low-bed trailer ...................................................................5
3.3 Lashing equipment .....................................................................................6
3.4 Loading .......................................................................................................7
3.5 Preparing the vehicle ..................................................................................8
4 Securing the load .......................................................................................9
4.1 Securing at the front ...................................................................................9
4.2 Securing at the rear - screed with side board ...........................................10
4.3 After transportation ...................................................................................11
5 Transportation ..........................................................................................12
5.1 Preparations .............................................................................................12
5.2 Driving mode ............................................................................................14
6 Loading by crane ......................................................................................15
7 Towing ......................................................................................................17
8 Safely parking the vehicle ........................................................................19
8.1 Lifting the vehicle with hydraulic lifts, lifting points ...................................20
D10.12 Operation ................................................................................1
1 Safety regulations .......................................................................................1
2 Controls ......................................................................................................3
2.1 Operating panel ..........................................................................................3
Flame monitoring (o) ............................................................................38
3 Remote control .........................................................................................42
4 Remote control ........................................................................................48
5 Malfunctions .............................................................................................56
5.1 Error code query for engine ......................................................................56

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Output of numerical code ..................................................................... 57
5.2 Fault codes .............................................................................................. 58
D30.12 Operation ................................................................................ 1
1 Control elements on the paver finisher ...................................................... 1
1.1 Control elements on the operator's control station ..................................... 1
Control platform ..................................................................................... 2
Running board extension (o) ................................................................. 3
Fuse box ................................................................................................ 4
Batteries ................................................................................................. 5
Main battery switch ................................................................................ 5
Hopper transport safeguard ................................................................... 6
Screed transport safeguard ................................................................... 6
Speed controller
Compacting elements ............................................................................ 7
Speed control, tamper (o) (A) ................................................................ 7
Speed regulation for vibration (B) .......................................................... 7
Conveying quantity controller
Auger / conveyor .................................................................................... 8
Paving thickness indicator .................................................................... 8
Auger lighting (o) ................................................................................... 9
LED working light (o) ............................................................................. 9
Auger height adjustment ratchet (o) .................................................... 10
Auger height displays .......................................................................... 10
Sensor rod / sensor rod extension ...................................................... 11
Manual separator fluid spray (o) .......................................................... 13
Separator fluid spraying system (o) ..................................................... 14
Conveyor limit switches ....................................................................... 15
Auger limit switches ............................................................................. 16
24 volt sockets (o) ............................................................................... 17
Fire extinguisher (o) ............................................................................. 18
First-aid kit (o) ...................................................................................... 18
Rotary beacon (o) ................................................................................ 19
D40.12 Operation ................................................................................ 1
1 Preparing for operation .............................................................................. 1
Required devices and aids .................................................................... 1
Before starting work
(in the morning or when starting paving) ............................................... 3
Check list for the vehicle operator ......................................................... 3
1.1 Starting the paver finisher .......................................................................... 6
Before starting the paver finisher ........................................................... 6
"Normal" starting .................................................................................... 6
External starting (starting aid) ................................................................ 9
After starting ........................................................................................ 12
Observe indicator lamps ...................................................................... 12
Battery charge indicator (1) ................................................................. 12
Error message (2) ................................................................................ 12

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1.2 Preparation for transportation ...................................................................14
Driving and stopping the paver finisher ................................................16
1.3 Preparations for paving ............................................................................17
Separator fluid ......................................................................................17
Screed heater .......................................................................................17
Direction marks ....................................................................................18
Loading/material transfer .....................................................................20
Filling function ......................................................................................20
1.4 Starting for paving ....................................................................................22
1.5 Checks during paving ...............................................................................23
Paver function ......................................................................................23
Quality of the layer ...............................................................................23
1.6 Interrupting/terminating operation ............................................................25
During breaks (e.g. the material supply truck is late) ...........................25
During longer breaks
(e.g. lunch break) .................................................................................25
When work is finished ..........................................................................27
1.7 Problems during paving ............................................................................28
1.8 Malfunctions on the paver finisher or screed ............................................30
E10.12 Set-up and modification ........................................................1
1 Special safety instructions ..........................................................................1
2 Distribution auger .......................................................................................3
2.1 Height adjustment ......................................................................................3
2.2 Auger width extension and material shaft with protective cover
(Optional equipment) ..................................................................................4
3 Cut-off shoe installation instructions ...........................................................6
Push roller crossbar,
adjustable ...............................................................................................9
4 Connecting the automatic levelling system ..............................................10
Connecting the slope controller / height controller ...............................11
5 Working with the remote control (o) .........................................................12
Changing over to normal control ..........................................................13
6 Limit switch ...............................................................................................14
6.1 Auger limit switches
Mount (left and right) ................................................................................14
F10 Maintenance .............................................................................1
1 Notes regarding safety ...............................................................................1
F2.12 Maintenance review ................................................................ 1
1 Maintenance review ...................................................................................1

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F3.12 Maintenance - conveyor ......................................................... 1
1 Maintenance - conveyor ............................................................................. 1
1.1 Maintenance intervals ................................................................................ 3
1.2 Points of maintenance ............................................................................... 4
Chain tension, conveyor (1) ................................................................... 4
Replace conveyor / conveyor drive - wear parts (2) .............................. 6
F4.12 Maintenance - auger assembly .............................................. 1
1 Maintenance - auger assembly .................................................................. 1
1.1 Maintenance intervals ................................................................................ 3
1.2 Maintenance points .................................................................................... 4
Drive chains of the
augers (1) .............................................................................................. 4
Auger box (2) ......................................................................................... 6
Seals and sealing rings (3) .................................................................... 7
Auger segments (4) ............................................................................... 8
F5.12 Maintenance - engine assembly ............................................ 1
1 Maintenance - engine assembly ................................................................ 1
1.1 Maintenance intervals ................................................................................ 3
1.2 Maintenance points .................................................................................... 6
Engine fuel tank (1) ............................................................................... 6
Engine lube oil system (2) .................................................................... 7
Engine fuel system (3) .......................................................................... 9
Engine air filter (4) ............................................................................... 11
Engine cooling system (5) ................................................................... 12
Engine drive belt (6) ............................................................................. 14
F6.12 Maintenance - hydraulic system ............................................ 1
1 Maintenance - hydraulic system ................................................................ 1
1.1 Maintenance intervals ................................................................................ 3
1.2 Points of maintenance ............................................................................... 5
Hydraulic oil tank (1) .............................................................................. 5
Suction/return flow hydraulic filter (2) .................................................... 7
High-pressure filter (3) ........................................................................... 8
Pump distribution gear (4) ..................................................................... 9
Bleeder ............................................................................................... 10
Hydraulic hoses (5) .............................................................................. 11
Marking hydraulic hoses / storage ’period, period of use .................... 13
Auxiliary flow filter (6) ........................................................................... 14

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F7.12 Maintenance - drive unit .........................................................1
1 Maintenance - drive unit .............................................................................1
1.1 Maintenance intervals ................................................................................3
1.2 Maintenance points ....................................................................................6
Chain tension (1) ....................................................................................6
Checking / adjusting chain tension - grease tensioner version ..............6
Checking / adjusting chain tension - spring loaded tensioner version ...8
Pre-tension of the tension unit. ..............................................................9
Adjusting tension: ...................................................................................9
Relieving the chain: ................................................................................9
Bottom plates (2) ..................................................................................10
Rollers (3) .............................................................................................11
Planetary gear (4) ................................................................................12
Screw connections ...............................................................................13
F8.12 Maintenance - electrical system ............................................1
1 Maintenance - electrical system .................................................................1
1.1 Maintenance intervals ................................................................................3
1.2 Maintenance points ....................................................................................4
Batteries (1) ............................................................................................4
Recharging the batteries ........................................................................5
Alternator (2) ..........................................................................................6
Insulation faults ......................................................................................8
Cleaning the alternator ...........................................................................9
2 Electrical fuses .........................................................................................10
2.1 Main fuses (1) ...........................................................................................10
2.2 Fuses in main terminal box (operating panel) ..........................................11
Relays ..................................................................................................13
F11.12 Lubricants and operating
substances ...............................................................................1
1 Lubricants and operating substances .........................................................1
1.1 Capacities ...................................................................................................3
2 Operating substance specifications ............................................................4
2.1 Notes on diesel fuel ....................................................................................4
2.2 Drive engine TIER III (o) - fuel specification ...............................................4
2.3 Drive engine TIER IV (o) - fuel specification ..............................................4
2.4 Engine - lubricating oil ................................................................................5
2.5 Cooling system ...........................................................................................5
2.6 Hydraulic system ........................................................................................5
2.7 Pump distribution gear ...............................................................................5
2.8 Drive unit planetary gear ............................................................................5
2.9 Auger box ..................................................................................................6
2.10 Grease .......................................................................................................6
2.11 Hydraulic oil ................................................................................................7

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F100 Tests, stopping ... ................................................................... 1
1 Tests, checks, cleaning, stopping .............................................................. 1
1.1 Maintenance intervals ................................................................................ 2
2 General visual inspection ........................................................................... 3
3 Check that the bolts and nuts fit firmly ....................................................... 3
4 Inspection by an expert .............................................................................. 3
5 Cleaning ..................................................................................................... 4
5.1 Cleaning the hopper ................................................................................... 5
5.2 Cleaning the conveyor and auger .............................................................. 5
6 Preserving the paver finisher ..................................................................... 6
6.1 Shutdowns for up to 6 months ................................................................... 6
6.2 Shutdowns lasting from 6 months to 1 year ............................................... 6
6.3 Recommissioning the machine .................................................................. 6
7 Environmental protection, disposal ............................................................ 7
7.1 Environmental protection ........................................................................... 7
7.2 Disposal ..................................................................................................... 7
8 Bolts - torques ............................................................................................ 8
8.1 Standard metric threads - strength class 8.8 / 10.9 / 12.9 ......................... 8
8.2 Fine metric threads - strength class 8.8 / 10.9 / 12.9 ................................. 9

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V 1
VPreface
Translation of the original operating instructions.
If the vehicle is to be operated safely, the information provided in these operating in-
structions will be required. The information is provided in a concise, clearly structured
form. The individual 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 vehicle options. Make sure that during op-
eration and maintenance work the description appropriate to the vehicle option is
used.
In the interest of continued development, the manufacturer reserves the right to make
changes to the vehicle (which will not, however, change the essential features of the
type of vehicle described) without updating the present operating instructions at the
same time.
Dynapac GmbH
Wardenburg
Ammerländer Strasse 93
D-26203 Wardenburg / Germany
Telephone: +49 / (0)4407 / 972-0
Fax: +49 / (0)4407 / 972-228
www.dynapac.com

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1 General safety instructions
1.1 Laws, guidelines, accident prevention regulations
AThe locally applicable laws, guidelines and accident prevention regulations must al-
ways be observed, even if these are not expressly named here.
The user himself/herself is responsible for compliance with the resulting regulations
and measures!
AThe following warnings, prohibitive symbols and instructive symbols indicate dangers
for persons, the vehicle and the environment due to residual risks when operating the
vehicle.
AFailure to observe this information, prohibitions and instructions can result in life-
threatening injuries!
AThe "Guidelines for the Correct Use and Application of Paver Finishers" compiled by
Dynapac must also be observed!

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1.2 Safety signs, signal words
In the safety instructions, the signal words "Danger", "Warning", "Caution", "Note" are
positioned in the coloured title block. They follow a certain hierarchy; in combination
with the warning symbol, they indicate the severity of the danger or the type of note.
"Danger"!
Danger of personal injury.
Indication of an immediately threatening danger that result in fatal or severe injuries
unless the corresponding actions are taken.
"Warning" !
Indication of a possible danger that can result in fatal or se-
vere injuries unless the corresponding actions are taken.
"Caution" !
Indication of a possible danger that result in moderate or mi-
nor injuries unless the corresponding actions are taken.
"Note" !
Indication of a possible drawback unless the corresponding
actions are taken, e.g. unwanted conditions or consequences can occur.
1.3 Other supplementary information
Other information and important explanations are identified by the following picto-
grams:
fPrecedes safety instructions that must be observed in order to prevent danger to per-
sonnel.
mPrecedes notes that must be observed to prevent damage to equipment.
APrecedes general notes and explanations.
DANGER
WARNING
CAUTION
NOTE

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1.4 Warnings
Warning on a dangerous area or hazard!
Failure to observe the warnings can result in life-threatening inju-
ries!
Warning on danger of being pulled in!
mIn this working area/on this element there is a danger of being pulled
in by rotating or conveying elements!
Only carry out activities with elements switched off!
Warning on dangerous electrical voltage!
mAll maintenance and repair work on the screed's electrical system
must always be carried out by an electrician!
Warning on suspended loads!
mNever stand under suspended loads!
Warning on danger of crushing!
mThere is a danger of crushing when certain components are operat-
ed, or certain functions or vehicle movements are carried out.
Always make sure that there are no persons within the endangered
areas!
Warning on hand injuries!
Warning on hot surfaces or hot liquids!

V 5
Warning on danger of falling!
Warning on dangers posed by batteries!
Warning on hazardous or irritating substances!
Warning on substances which constitute a fire hazard!
Warning on gas bottles!

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1.5 Prohibitive symbols
Opening/walking on/reaching in/carrying out/setting up are prohibit-
ed during operation or while the drive engine is running!
Do not start engine/drive!
Maintenance and repair work may only be carried out with the diesel
engine shut down!
Spraying with water is prohibited!
Extinguishing with water is prohibited!
Unauthorised maintenance is prohibited!
Only qualified experts may conduct maintenance!
AConsult the Dynapac Service Department
Fire!, naked flames and smoking are prohibited!
Do not switch!

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1.6 Protective equipment
ALocally applicable regulations may require the wearing of various safety equipment!
Always observe these regulations!
Wear safety goggles to protect your eyes!
Wear suitable head protection!
Wear suitable hearing protection to protect your hearing!
Wear suitable safety gloves to protect your hands!
Wear safety shoes to protect your feet!
Always wear close-fitting work clothing!
Wear a warning vest to be seen in time to avoid accidents!
Wear respiratory equipment if breathing air is contaminated!

V 8
1.7 Environmental protection
AThe locally applicable laws, guidelines and accident prevention regulations for the
proper recycling and disposal of waste must always be observed, even if these are
not expressly named here.
Water-endangering substances like:
- Lubricants (oil, grease)
- Hydraulic oil
-Dieselfuel
- Coolant
- Cleaning liquids
must not get into the soil or sewer system during cleaning, maintenance and repair
work!
Substances must be caught, stored, transported and brought to pro-
fessional disposal sites in suitable containers!
Environmentally hazardous substance!
1.8 Fire prevention
ALocally applicable regulations may require suitable extinguishing agents to be carried
on the vehicle!
Always observe these regulations!
Fire extinguisher!
(optional equipment)

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1.9 Additional information
mAlso observe the manufacturer's documentation and additional doc-
umentation!
AFor example, the maintenance instructions of the engine manufac-
turer
mDescription / depiction applicable when equipped with gas heater!
mDescription / depiction applicable when equipped with electric heat-
er!
tUsed to indicate standard equipment.
oUsed to indicate optional equipment.

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2 CE identification and Declaration of Conformity
(only applies to machines sold in the EU/EEC)
This machine has CE identification. This identification says that the machine fulfils the
basic health and safety requirements pursuant to the Machinery Directive 2006/42/
EC together with all other valid regulations. The scope of supply of the machine in-
cludes a Declaration of Conformity as specified in the valid regulations and amend-
ments together with harmonised standards and other valid provisions.
3 Guarantee conditions
AThe guarantee conditions are included in the scope of supply of the machine.
This contains a complete specification of the valid conditions.
The guarantee becomes null and void if
- damage occurrs through malfunctions caused by improper use and incorrect oper-
ation.
- repairs or manipulations are carried out by persons who are neither trained nor au-
thorised accordingly.
- accessories or spare parts are used that cause damage and which are not ap-
proved by Dynapac.