Dynapac F1000T Troubleshooting guide

08FEB2010
OPERATION
&
MAINTENANCE
Keep this manual for future reference
Order number for this manual: D717.41.00.38
Paver
F1000T
Type 717

VALUE
QUALITY
THE ORIGINAL
Your Authorized Dynapac Dealer:

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US_track_10ftIVZ.fm 1-6 - 02-0103
Table of contents
V Preface ..................................................................................... 1
1 General 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
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 Technical data, standard configuration ...................................................... 7
4.1 Dimensions ................................................................................................ 7
4.2 Allowed angle of rise and slope ................................................................. 8
4.3 Permissible approach angle ....................................................................... 8
4.4 Weights, F1000T ....................................................................................... 9
4.5 Performance data ..................................................................................... 9
4.6 Engine ...................................................................................................... 10
4.7 Hydraulic system ...................................................................................... 10
4.8 Material compartment (hopper) ................................................................ 10
4.9 Electrical system ...................................................................................... 10
4.10 Operator stations ..................................................................................... 10
4.11 Conveyors ................................................................................................ 11
4.12 Auger ....................................................................................................... 11
4.13 Permissible temperature ranges .............................................................. 11
5 Location of instruction labels and identification plates ............................. 12
5.1 Identification label for the paver (6) ....................................................... 16
6 EN standards ........................................................................................... 17
6.1 Continuous sound pressure level on the F1000T Track Paver, Cummins
QSB-6.70 Tier III Engine. 17
6.2 Operating conditions during measurement .............................................. 17
6.3 Measuring point configuration .................................................................. 17
C1.0 Transport ................................................................................. 1
1 Safety regulations for transportation .......................................................... 1
2 Transportation on low-bed trailers ............................................................. 3
2.1 Preparations ............................................................................................... 3
2.2 Driving onto the low-bed trailer .................................................................. 6
2.3 Secure the paver to the low-bed trailer: ..................................................... 6
2.4 After transportation .................................................................................... 7
3 Transportation ............................................................................................ 8

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3.1 Preparations ............................................................................................... 8
3.2 Driving mode ............................................................................................ 11
4 Loading by crane ..................................................................................... 13
5 Towing ..................................................................................................... 15
6 Safely parking the vehicle ........................................................................ 16
D 1.0 Operation ................................................................................. 1
1 Safety regulations ...................................................................................... 1
2 Controls ...................................................................................................... 2
2.1 Operating panel ......................................................................................... 2
3 Auxiliary functions .................................................................................... 25
4 Left / right remote controls and handsets ................................................. 27
Left / right remote control ..................................................................... 28
D2.0 Operation ................................................................................. 1
1 Operation 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
1.2 Engine Error messages ........................................................................... 18
1.3 FMI-codes ................................................................................................ 23

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D3.0 Operation ................................................................................. 1
1 Operating 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
1 Preparation 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
When work is finished .......................................................................... 21
2 Malfunctions ............................................................................................. 22
2.1 Problems during paving ........................................................................... 22

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2.2 Malfunctions on the paver or screed ........................................................ 24
E01 Set-up and modification ......................................................... 1
1 Special notes on safety .............................................................................. 1
2 Auger ......................................................................................................... 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
3 Screed ........................................................................................................ 8
4 Electrical 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
F1.0 Maintenance ............................................................................ 1
1 Notes regarding safety ............................................................................... 1
F2.0 Maintenance overview ............................................................ 1
1 Maintenance overview ............................................................................... 1
F3.0 Maintenance - Conveyor ........................................................1
1 Maintenance - 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
1 Maintenance - 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
Auger bevel gear (on the RH and LH sides) (4) .................................... 5
Auger blade (5) ...................................................................................... 6
F5.0 Maintenance - Engine .............................................................1

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1 Maintenance - 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
1 Maintenance - hydraulic system ................................................................ 1
1.1 Maintenance intervals ................................................................................ 2
1.2 Hydraulic System ....................................................................................... 3
1.3 Points of maintenance ............................................................................... 3
Hydraulic oil tank (1) .............................................................................. 3
Suction/return flow hydraulic filter (2) .................................................... 5
Venting the filter: .................................................................................... 6
High pressure filter (3) ........................................................................... 7
Pump distribution gear (4) ..................................................................... 8
Hydraulic hoses (5) .............................................................................. 10
F7.0 Maintenance - Track ............................................................... 1
1 Maintenance - running gear ....................................................................... 1
1.1 Maintenance intervals ................................................................................ 2
2 Instructions for undercarriage maintenance ............................................... 3
2.1 Long-term effect of parked machines ........................................................ 4
2.2 Maintenance .............................................................................................. 5
Idlers, guide rollers, drive (1) ................................................................. 5
Guide rollers - straight running, secure the adjustment bolts (2) ........... 6
Planetary gear (3) .................................................................................. 7
Idler rollers, front (4) .............................................................................. 8
2.3 Lubricants and fuels ................................................................................... 9
2.4 Filling volumes ........................................................................................... 9
F8.0 Maintenance - Electronic system ..........................................1
1 Maintenance - 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
1 Maintenance - Lubricating points ............................................................... 1
1.1 Maintenance intervals ................................................................................ 2
1.2 Points of maintenance ............................................................................... 3
Bearing points (1) .................................................................................. 3

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F10.0 Checks, decommissioning .....................................................1
1 Tests, check-up, cleaning, stopping ........................................................... 1
1.1 Maintenance intervals ................................................................................ 2
2 General observation ................................................................................... 3
3 Check performed by a specialist ................................................................ 3
4 Cleaning ..................................................................................................... 4
5 Preservation 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
1 Lubricants and operating substances ....................................................... 1
1.1 Capacities .................................................................................................. 2

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V_01_US.fm
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 sever 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.

V 2
V_01_US.fm
Dynapac USA, Inc.
2100 N. First Street
Garland, Texas 75040
Telephone: [phone]
Fax: [phone]
www.dynapac.com