Page 1 OPERATION & MAINTENANCE Screed Dynapac V5100TV-(E) / V6000TV-(E) Type 616 / 617 4812038290 (A5) / 4812038295 (A4) 01-0111 Keep for later use in document compartment Valid for: _________________ - _________________ _________________ - _________________...
Page 2 www.atlascopco.com...
Page 3: Table Of Contents
Table of contents Preface ..................1 General safety instructions ................ 2 Laws, guidelines, accident prevention regulations ........2 Warnings ....................2 Prohibitive symbols ..................4 Protective equipment ................. 5 Environmental protection ................6 Fire prevention ................... 6 Additional information ................7 CE identification and Declaration of Conformity ........
Page 4 Notes regarding safety ................1 Operation of the screed ................2 Extend/retract screed .................2 Adjusting the compacting elements - conventional version ......4 Adjusting the tamper ................4 Adjusting the vibration ................4 Adjusting the tamper - PLC version ............5 Adjusting the vibration ................5 Operation of the gas heater system with flame monitoring ......6 Schematic diagram of the gas supply system ..........6 General notes on the gas heater system ...........7 Connection and leak test ................8...
Page 5 Notes regarding safety ................1 Mounting the screed to the paver finisher ..........2 Mounting the side shields ................3 Mount side shield, hinged (o) ..............4 Installation, hinge ................... 4 Installation, working position ..............5 Transport position .................. 6 Adjusting the side shield height and support angle ........
Page 6 Lubrication points ..................5 Tamper and vibration bearings ..............5 Guide tubes ....................6 Other lubricating and maintenance points ..........8 Checkpoints ....................9 Guides of the extendable parts ..............9 Adjustment of guide tube play ..............9 Cleaning the screed .................10 Emptying the tamper compartment ............10 Removing the tamper deflector plates ..........11 Checking / adjusting the tamper deflector plate ........12 Hydraulic hoses ..................12...
Page 7: Preface
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...
Page 8: General Safety Instructions
Failure to observe this information, prohibitions and instructions can result in life- threatening injuries! The "Guidelines for the Correct Use and Application of Paver Finishers" compiled by Dynapac must also be observed!
Page 9 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 Danger of personal injury.
Page 10: Warnings
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! In 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! All maintenance and repair work on the screed's electrical system...
Page 11 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!
Page 12: Prohibitive Symbols
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! Consult the Dynapac Service Department Fire!, naked flames and smoking are prohibited! Do not switch!
Page 13: Protective Equipment
Protective equipment Locally 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!
Page 14: Environmental Protection
Environmental protection The 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 - Diesel fuel - Coolant - Cleaning liquids...
Page 15: Additional Information
Additional information Also observe the manufacturer's documentation and additional doc- umentation! For example, the maintenance instructions of the engine manufac- turer Description / depiction applicable when equipped with gas heater! Description / depiction applicable when equipped with electric heat- t Used to indicate standard equipment. o Used to indicate optional equipment.
Page 16: Ce Identification And Declaration Of Conformity
- 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. V 10...
Page 17: Residual Risks
Residual risks These are risks that remain even if all possible measures and safety precautions have been taken to help minimise dangers (risks) or to reduce their probability and scope to zero. Residual risks in the form of - Danger to life and limb of persons at the machine - Danger to the environment posed by the machine - Damage to property and restricted output and functionality of the machine - Damage to property in the operating range of the machine...
Page 18: Sensibly Predictable Incorrect Usage
Sensibly predictable incorrect usage Every kind of sensibly predictable incorrect usage of the machine constitutes misuse. Incorrect usage makes the manufacturer's warranty null and void: the operator bears sole responsibility. Sensibly predictable incorrect usage of the machine includes: - presence in the danger zone of the machine - transporting persons - leaving the operator's platform while the machine is operating - removing protection or safety devices...
Page 19: A Correct Use And Application
A Correct use and application The "Guidelines for the Correct Use and Application of Paver Finishers" 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 heeded.
Page 21: B Description Of The Screed
B Description of the screed Application The Dynapac V5100TV / V6000TV attached screed is operated in conjunction with a paver finisher. The screed is used for laying: - bitumen materials, - roll-down concrete or lean-mixed concrete, - track-laying ballast or - unbound mineral aggregates for foundations for paving.
Page 22: Assemblies
Assemblies Tamper and vibration elements: The tamper knives converging in the middle area prevent seams in the middle. Auxiliary vibration (option) supports the compacting process, thus improving the tex- ture. The tamper and the vibration elements can be individually switched on and off and controlled with regard to speed.
Page 23 Lubricating system: All important lubricating points on the main screed are com- prised to form central distribution blocks. This system facilitates lubrication and reduc- es the time required for maintaining the screed. The extendable parts have individual lubricating points for the application of lubricat- ing grease.
Page 24: Safety
Safety The safety devices of the paver finisher and of the screed are described in chapter B, section 3 of the operating instructions for the paver finisher. Remaining risks at the screed Danger of squeezing! At all moving parts of the screed, there is a danger of crushing, trap- ping or shearing.
Page 25 Danger of burning! Heating the screed heater leads to danger due to hot surfaces, par- ticularly on the bottom plates and side shields. Keep away from these parts! Or wear protective gloves! - Always wear all protective clothing required! Failure to wear protective clothing or wearing protective clothing in an improper manner can be dangerous to health.
Page 26: Technical Data
Technical data Dimensions V5100 V6000 Basic width 2.55 3.00 Working width: min. width with 2 cut-off shoes 2.00 2.50 hydraulically extendable to 5.10 6.00 Depth of the bottom plates: Main screed extendable parts As regards extension of the screed, refer to the chapter entitled "Set-up and modifi- cation".
Page 27: Adjustment/Equipment Features
Adjustment/equipment features Crowning: - Adjustment range -2.0%... +4.5% - Adjusting mechanism with ratchet via chain with hydraulic motor via chain (o) Height/angle adjustment of extendable parts 4-point spindle adjustment Hinged walkway plate Standard Lubrication system: Individual lubrication points and central lubrication system Compacting system Tamper system Vertical impact tamper...
Page 28: Gas Heater System V 5100
Gas heater system V 5100 Fuel (liquefied gas) Propane gas Burner type Flame band burner Electronic ignition, Heater control system flame monitoring, (switch cabinet on the screed) temperature monitoring (o) Gas bottles (on the screed) 2 units - Capacity per bottle 78 l - Gross weight per bottle 33 kg...
Page 29: Electric Heater V 5100 (O)
Electric heater V 5100 (o) Electric heater with heating Type of heating strips in bottom plates and tamper knives Number of heating strips - On each bottom plate items - On each tamper blade - Per side shield (O) Screed heating system total output: - Main screed and extendable parts 18,000 - 350mm extension part...
Page 30: Location Of Instruction Labels And Type Plates
Location of instruction labels and type plates B 10...
Page 31: Warning Signs
Warning signs No. Pictogram Meaning Warning - Danger of crushing! Crushing points can cause severe or fa- tal injuries! Maintain a safe distance from the dan- ger area! Warning - Hot surface - Danger of burning! Hot surfaces can cause severe injuries! Keep your hands at a safe distance from the danger area! Use protective clothing or protective equipment!
Page 32: Further Warnings And Operating Instructions
Further warnings and operating instructions No. Pictogram Meaning - Important! Danger due to dangerous electrical vol- tage. The machine personnel must check the insulation monitoring every day before starting the machine! Failure to comply with the daily routine can cause severe or fatal injuries.
Page 33: Screed Type Plate (7)
Screed type plate (7) Item Designation Screed type Maximum operating weight of the screed Screed number Year of construction Manufacturer B 13...
Page 34 B 14...
Page 35: C Transportation
C Transportation Safety regulations for transportation Accidents can happen when the paver finisher and the screed are not properly pre- pared for transportation or when transportation is carried out improperly! Retract the extension parts of the screed to the basic width and remove all extension parts that may have been attached.
Page 36: Transporting The Removed Screed
Transporting the removed screed The procedure required to load and transport the screed when installed on the paver finisher is described in the operating instructions for the paver finisher. The screed must be retracted to the basic width. All protruding or loose parts and the gas bottles for the screed heating system (o) (see Chapters E and D) must be re- moved.
Page 39: D Operation
D Operation Notes regarding safety Improper operation of the screed or the screed heater can endanger persons. - Ensure that all protective devices and covers are available and appropriately se- cured! - Immediately rectify damage which as been ascertained! Operation must not be continued when the vehicle is defective! - Always ensure that no person is endangered when working! - Do not let any person ride along on the screed!
Page 40: Operation Of The Screed
Operation of the screed For all general functions of the paver fin- isher and the screed that are not special- ly related to the present screed, refer to the operating instructions of the paver finisher. Extend/retract screed To extend or retract the hydraulically ad- justable extension parts, - actuate the switch (1) on the remote controls installed on the right-hand...
Page 41 - A pointer (2) and a scale (3), from which the extended width can be read off, can be found on each of the ex- tendable parts.
Page 42: 2.2 Adjusting The Compacting Elements - Conventional Version
2.2 Adjusting the compacting elements - conventional version Adjusting the tamper The tamper function is switched on and off using the switch (4) on the paver fin- isher's operating panel (see paver finish- er operating instructions). The tamper frequency (number of strokes per minute) is set using the rota- ry regulator (6).
Page 43: 2.3 Adjusting The Tamper - Plc Version
2.3 Adjusting the tamper - PLC version The tamper function is switched on and off using the button (8) on the paver fin- isher's operating panel (see paver finish- er operating instructions). The tamper frequency (number of strokes per minute) is set and displayed in the paver finisher control system / re- mote control compacting element setting menu (see paver finisher operating in-...
Page 44: Operation Of The Gas Heater System With Flame Monitoring
Operation of the gas heater system with flame monitoring Schematic diagram of the gas supply system Item Designation Gas bottles Bottle valves Pressure reducer with pressure gauge Hose break safety devices Hose connections Pipe connections Flame band burner Solenoid valves Hose couplings for extension parts Quick action valves...
Page 45: General Notes On The Gas Heater System
General notes on the gas heater system The heater of the screed burns propane gas (liquefied gas). The two gas bottles are on the screed. The heater is equipped with an electronic flame and temperature monitoring system. The spark plug on the burner simultaneously serves to monitor the flame. The switch cabinet is mounted on the screed.
Page 46: Connection And Leak Test
Connection and leak test The gas pipe system of the main screed and the extendable parts is permanently installed. To connect the gas bottles: - Unscrew the protective caps from the bottle valves and screw onto the rear of the bottle bracket. - Check whether the quick action valves are closed.
Page 47: Commissioning And Checking The Heater
Commissioning and checking the heater The gas heating system is operated with two gas bottles. - Check whether the battery master switch is switched on. - Open the bottle valves (21). Unlock the safety valve by pressing the hose break safety device (20). - Open the quick action valves.
Page 48: Exchanging The Gas Bottles
Exchanging the gas bottles - Check whether the quick action valves and both bottle valves (21) are closed. - Unscrew the gas hoses. - Screw the protective caps for the bot- tle valves onto the gas bottles. - Screw pressure reducer onto the available mounting bracket.
Page 49: Screed Heater - Conventional Version
Screed heater - conventional version Switch cabinet for screed heater D 11...
Page 50 Item Designation Heater ON (button) - This opens the non-return valves for the gas supply to the burners and activates the electronic ignition system and the flame monitoring sys- tem. Heater OFF (button) This closes the non-return valves for the gas supply to the burners and switches off the electronic ignition system and the flame monitoring sys- tem.
Page 51: Ignition Process
Ignition process - Actuate the on/off switch (30) in the switch cabinet; this - opens the electromagnetic non-re- turn valves for the gas supply to the burners; - activates the electronic ignition sys- tem, causing the gas to be automat- ically ignited by the spark plugs and controlled by the flame monitoring system.
Page 52: Function Of The Flame Monitoring System
Function of the flame monitoring system Item Designation Left middle section malfunction display, red Left extendable part malfunction display, red Right middle section malfunction display, red Right extendable part malfunction display, red Ignition boxes on the individual screeds Red indicator lamp on the ignition box in the corresponding screed Yellow indicator lamp on the ignition box in the corresponding screed D 14...
Page 53 Via the temperature sensor and flame monitoring system, the electronics monitor gas heater operation. If there is no stable flame at the ignition burner within 7 seconds, the electronics indicate a malfunction. The gas supply is interrupted and the red indi- cator lamps on the ignition box and in the switch cabinet light up.
Page 54: Switching Off The Heater
Switching off the heater After work has been completed, or when the heater is no longer required: - Switch off the On/Off switch (31) in the switch cabinet. - Close the quick action valves and both bottle valves. If these valves are not closed, there is a danger of fire and explosion due to the possible escape of uncombusted gas! Always close the valves during breaks...
Page 55: Screed Heater - Plc Version
Screed heater - PLC version Switch cabinet for screed heater D 17...
Page 56 Item Designation Control and monitoring unit - For actuating the heating system, setting and monitoring the set tem- perature. Left middle section malfunction display, red Left extendable part malfunction display, red Right middle section malfunction display, red Right extendable part malfunction display, red D 18...
Page 57: Operating The Control And Monitoring Unit
Operating the control and monitoring unit D 19...
Page 58 Item Designation / function - Screed section selection For selecting the screed sections for temperature display and adjustment. The temperature is adjusted for all sections together. - "Energy saving" selection To reduce the heater output. After switching on, the "Energy saving" status (ON/OFF) set during previous operation is assumed again.
Page 59 Item Designation / function - "Sensor error" warning lamps Warning lamps 1-4 for the individual screed sections light up if a defect is present on the corresponding sensor. Check sensor. The controller operates in the emergency programme. - Heater status display Indicator lamps 1-4 for the individual screed section heaters light up if the corresponding heater circuit is engaged.
Page 60: Ignition Process
Ignition process - PLC version - Actuate the on/off switch (50) in the switch cabinet; this - opens the electromagnetic non-re- turn valves for the gas supply to the burners; - activates the electronic ignition sys- tem, causing the gas to be automat- ically ignited by the spark plugs and controlled by the flame monitoring system.
Page 61: Function Of The Flame Monitoring System
Function of the flame monitoring system Item Designation Left middle section malfunction display, red Left extendable part malfunction display, red Right middle section malfunction display, red Right extendable part malfunction display, red Ignition boxes on the individual screeds Red indicator lamp on the ignition box in the corresponding screed Yellow indicator lamp on the ignition box in the corresponding screed D 23...
Page 62 Via the temperature sensor and flame monitoring system, the electronics monitor gas heater operation. If there is no stable flame at the ignition burner within 7 seconds, the electronics indicate a malfunction. The gas supply is interrupted and the red indi- cator lamps on the ignition box and in the switch cabinet light up.
Page 63: Temperature Display, Setting Temperature Level
Temperature display, setting temperature level The temperature display and temperature level setting for the screed heater are car- ried out on the control and monitoring unit in the screed heater's switch cabinet. Temperature setting - Press button (47) or (48) to show the current nominal temperature on the display (52).
Page 64: Energy Saving Mode / "Energy Saving
Energy saving mode / "Energy saving" In this operating status, not all of the different screed sections' heaters are active at the same time. Switching is carried out via temperature regulation. Whenever the nominal tempera- ture is achieved in an actively heated section, the control system switches these sec- tions off and activates those with the lowest temperature.
Page 65: Status And Error Messages
Status and error messages When an error occurs, the warning lamp (53) for the affected screed section lights up and the controller runs in an emergency programme. A warning signal is additionally sounded. The warning signal is acknowledged with the minus button (48). After pressing the Enter button, an error code is shown on the display (52).
Page 66: Emergency Programme With Sensor Error
Error code Cause of error Measure Error messages without button call-up Warning lamp - Check sensor, (53-1) - Sensor F1 defective the controller operates in lights up the emergency programme Warning lamp - Check sensor, (53-2) - Sensor F2 defective the controller operates in lights up the emergency programme...
Page 67: Switching Off The Heater
Switching off the heater After work has been completed, or when the heater is no longer required: - Press the on/off button (50) in the switch cabinet. - Close the quick action valves and both bottle valves. If these valves are not closed, there is a danger of fire and explosion due to the possible escape of uncombusted gas! Always close the valves during breaks...
Page 68: Operating The Electric Heater
Operating the electric heater Switch cabinet for screed heater 4 x 230 V 98 99 The configuration of individual elements may vary slightly! D 30...
Page 69 Item Designation EMERGENCY STOP button Test key for monitoring of insulation and indicator lamp for insulation defects Reset key for insulation monitoring Generator indicator lamp Heating ON/OFF (o) Circuit breaker for heating section 1 Circuit breaker for heating section 2 Circuit breaker for heating section 3 Circuit breaker for heating section 4 Heating section 1 indicator lamp...
Page 70: Operating The Control And Monitoring Unit
Operating the control and monitoring unit D 32...
Page 71 Item Designation / function - Screed section selection For selecting the screed sections for temperature display and adjustment. The temperature is adjusted for all sections together. - "Energy saving" selection To reduce the heater output if the generator output is insufficient. After switching on, the "Energy saving"...
Page 72 Item Designation / function - "Sensor error" warning lamps Warning lamps 1-4 for the individual screed sections light up if a defect is present on the corresponding sensor. Check sensor. The controller operates in the emergency programme. - Heater status display Indicator lamps 1-4 for the individual screed section heaters light up if the corresponding heater circuit is engaged.
Page 73: General Information On The Heating System
General information on the heating system The electric heating system is supplied with power by a generator on board the paver finisher which is controlled fully- automatically in accordance with re- quirements. Heating resistors in the form of heating strips ensure direct temperature transi- tion and even distribution of heat.
Page 74: Energy Saving Mode / "Energy Saving
Energy saving mode / "Energy saving" Under certain conditions, e.g. large working widths, it is sensible to activate energy saving mode. In this operating status, not all of the different screed sections' heaters are active at the same time. Switching is carried out via temperature regulation. Whenever the nominal tempera- ture is achieved in an actively heated section, the control system switches these sec- tions off and activates those with the lowest temperature.
Page 75: Insulation Monitor
Insulation monitor The function of the protective insulation monitoring measure must be checked every day before starting work. This check only checks the function of the insulation monitor, not whether an in- sulation error has occurred on the heat- ing sections or consumers. - Start the paver finisher's drive engine.
Page 76: Insulation Faults
Insulation faults If an insulation fault occurs during operation, and the indicator lamp displays an insu- lation fault, the operator may proceed as follows: - Switch the switches of all external equipment and the heater to OFF and press the reset button for at least 3 seconds to delete the fault.
Page 77: Commissioning And Checking The Heater
Commissioning and checking the heater In order to reach the required tempera- ture, the heater should be switched on approx. 15 - 20 minutes before the start of paving. - Switch on the paver finisher's engine. - Switch on heating system ON / OFF switch (74) (o).
Page 78: Temperature Display, Setting Temperature Level
Temperature display, setting temperature level The temperature display and temperature level setting for the screed heater are car- ried out on the control and monitoring unit in the screed heater's switch cabinet. Temperature setting - Press button (102) or (103) to show the current nominal temperature on the display (107).
Page 79: Status And Error Messages
Status and error messages When an error occurs, the warning lamp (108) for the affected screed section lights up and the controller runs in an emergency programme. A warning signal is additionally sounded. The warning signal is acknowledged with the minus button (103). After pressing the Enter button, an error code is shown on the display (5).
Page 80: Emergency Programme With Sensor Error
Error code Cause of error Measure Error messages without button call-up Warning lamp - Check sensor, - Sensor F1 defective the controller operates in lights up the emergency programme Warning lamp - Check sensor, - Sensor F2 defective the controller operates in lights up the emergency programme Warning lamp...
Page 81: Switching Off The Heater
Switching off the heater After work has been completed, or when the heater is no longer required: - Switch off the electrically heated side shields' (o) ON / OFF switch (83). - Switch on the control and monitoring unit ON / OFF switch (105). - Switch off ON/OFF switch (74) of heating system (o).
Page 82: Malfunctions
Malfunctions Problems during paving Problem Reason - change in the material temperature, demixing - wrong material composition - incorrect operation of the roller - incorrectly prepared foundation - long standstill times between loads - grade control reference line is not suitable - grade control jumps to the reference line Wavy surface - grade control toggles between up and down...
Page 83 Problem Reason - material temperature is too low - change in the material temperature - moisture on the foundation - demixing Cracks in the layer (over the entire - wrong material composition width) - wrong layer height for maximum grain size - cold screed - bottom plates of the screed are worn or warped - paver finisher speed is too high...
Page 84 Problem Reason - material temperature - change in the material temperature - wrong layer height for maximum grain size screed does not - incorrect installation of the grade control react as expected to corrective - vibration is too slow measures - screed is not operated in the floating position - too much play in the mechanical screed link - paver finisher speed is too high...
Page 85: Malfunctions On The Screed
Malfunctions on the screed Malfunction Reason Remedy Tamper is obstructed by cold Properly heat the screed bitumen Hydraulic oil level in the tank Top up the oil is too low Replace the valve; if neces- Pressure limiting valve is de- sary, repair and adjust the Tamper or vibra- fective...
Page 86 D 48...
Page 87: E Set-Up And Modification
E Set-up and modification Notes regarding safety Inadvertent starting of the paver finisher can endanger persons working on the screed. Only carry out such work with the paver finisher motor at a standstill unless the in- structions state the opposite! Ensure that the paver finisher is secured to prevent unintentional starting.
Page 88 Mounting the screed to the paver fin- isher - Place the screed on a suitable support (squared timber sections, etc.) and back up the paver finisher to the screed. - Lower the crossbeams and position them in such a manner that the cross- beam shackles (1) are located above the required attaching points (2) on the screed.
Page 89: Mounting The Side Shields
Mounting the side shields The side shields are only mounted once all other mounting and adjustment work on the screed has been completed. - Secure the side shields to the screed with the assembly parts provided (1). - Secure the front mounting bracket (2) in the top position with the cotter pin (3). - Attach the lower section of the side shield (4) to the chains (6) of the upper section via the former's hooks (5).
Page 90: Mount Side Shield, Hinged (O)
Mount side shield, hinged (o) Installation, hinge - Guide the hinge (1) with the already premounted angle bracket (2) against the in- side of the extendable part and fasten to the screed using the provided assembly parts (3). Do not screw the assembly parts of the hinge and angle bracket (3) tight until the hin- ged side shields have been fitted and aligned in the working position to start with!
Page 91: Installation, Working Position
Installation, working position - Dismantle the lower part of the side shield: - Lower side shield using crank (4). - Secure the front mounting bracket (5) in the top position with the cotter pin. - Unhinge the lower part of the side shield (6) from the chains of the upper part. When swivelling the side shields in, a journal (7) engages on a support surface (8) of the extendable screed part and simplifies installation.
Page 92: Transport Position
Transport position...
Page 93 The following steps must be carried out to enable the side shields to be folded in front of the walkway plates when swivelled up: - Dismantle the lower part of the side shield: - Lower side shield using crank (4). - Secure the front mounting bracket (5) in the top position with the cotter pin.
Page 94: Mounting The Edge Compactor
Adjusting the side shield height and support angle The height and support angle of the side shield can be adjusted with the aid of the crank (1). - Knob (2) in top position: Adjustment of the support angle. - Knob (2) in bottom position: Adjust- ment of the height.
Page 95: Mounting The Cut-Off Shoe
Mounting the cut-off shoe Cut off shoes for operating widths of less than the basic width can be secured to the lower sections of the side shields. - Lower side shield onto cut-off shoe (1). - Use retaining rod (2) to join cut-off shoe and side shield together (hole (3)).
Page 96: Adjusting The Crowning
Adjusting the crowning The screed is equipped with a spindle that can be used to set the required crowning. - Open centre cover (1) of the screed. - Operate ratchet lever (2) until the desired crowning is set. - Check the set angle against the scale (3).
Page 97: Electrical Connections
Electrical connections On the rear wall of the paver finisher: - Plug connector (1) for the electrical consumers on the screed on the screed heater's screed switch cabinet. - Secure the positioned connector using the locking clips on the socket. - PLC electronics: Additionally establish plug connection (2).
Page 98: Connection For The Electric Heater (O)
Connection for the electric heater (o) On the lower side of the switch cabinet: - Connect the connectors for the indi- vidual heater circuits (1) to the rele- vant sockets. - Secure the positioned connector using the locking clips on the socket. - Insert temperature sensor connectors (2).
Page 99: Screed Extension V5100
Screed extension V5100 Expansion - extension parts 2.55 2.55 - 5.1 m 3.25 - 5.8 m 4.05 - 6.6 m 4.75 - 7.3 m 5.55 - 8.1 m 6.25 - 8.8 m E 13...
Page 100: Assembly Parts - Extension Parts
Assembly parts - extension parts Connection Screed - extension part / extension part – extension part Connection shafts Article No.: 4812035437 Vibration (1a) Connection shafts Article No.: 4720004332 Tamper (1b) Connection shafts Article No.: 614217500 Vibration (2a) Connection shafts Article No.: 614217600 Tamper (2b) Clutch crown wheel (3) Article No.: 4749400265...
Page 101: Extension - Material Guide Plates V5100
Extension - material guide plates V5100 Required material guide plates Brace II per side Braces I + II 3.55 - 5.1 m 4.55 - 5.8 m 1000+ 4.55 - 6.6 m 1000+ 5.55 - 7.3 m 1000+ 6.55 - 8.1 m 1000 1000+ 7.55 - 8.8 m...
Page 102: Assembly Parts - Material Guide Plates
Assembly parts – material guide plates Connection Assembly parts for screed / material guide plate (6) - 3 x hex bolts, Art. No.: D938111728 (6a) - 2 x bolt locking devices, Art. No.: 4749901809 (6b) - 2 x bushes, Art. No.: 4730010815 (6c) - 1 x washer, Art.
Page 103 Assembly description – extension parts, material guide plates, side shields E 17...
Page 104: Screed Extension V6000
Screed extension V6000 Expansion - extension parts 10.0 ..3.0 - 6.0 m 3.7 - 6.7 m 4.5 - 7.5 m 5.2 - 8.2 m 4.5 - 7.5 m 6.0 - 9.0 m 6.7 - 9.7 m E 18...
Page 105: Assembly Parts - Extension Parts
Assembly parts - extension parts Connection Screed - extension part / extension part – extension part Connection shafts Article No.: 4812035437 Vibration (1a) Connection shafts Article No.: 4720004332 Tamper (1b) Connection shafts Article No.: 614217500 Vibration (2a) Connection shafts Article No.: 614217600 Tamper (2b) Clutch crown wheel (3) Article No.: 4749400265...
Page 106: Extension - Material Guide Plate V6000
Extension - material guide plate V6000 Required material guide plates Brace II per side Braces I + II 4.0 - 6.0 m 6.0 - 6.7 m 1000+ 6.0 - 7.5 m 1000+ 7.0 - 8.2 m 1000 1000+ 8.0 - 9.0 m 1000 1000+ 8.0 - 9.7 m...
Page 107: Assembly Parts - Material Guide Plates
Assembly parts – material guide plates Connection Assembly parts for screed / material guide plate (6) - 3 x hex bolts, Art. No.: D938111728 (6a) - 2 x bolt locking devices, Art. No.: 4749901809 (6b) - 2 x bushes, Art. No.: 4730010815 (6c) - 1 x washer, Art.
Page 108 Assembly description – extension parts, material guide plates, side shields E 22...
Page 109: Adjusting Extendable Parts
Adjusting extendable parts To ensure that the screed lays without marks and the extendable parts can also be adjusted to the various operating conditions during use, the height of the extendable parts can be adjusted. The approach angle of the extendable parts is pre-set in the factory.
Page 110: Adjusting The Approach Angle Of The Extendable Parts
Adjusting the approach angle of the extendable parts The middle sections and extendable screed parts are adjusted parallel to each other at the factory. The positioning angle of the extendable screed parts can be varied in relation to the middle sections if required: - Loosen cheese head screws (1) and remove locking plate (2).
Page 111: Extending The Screed
Extending the screed Mounting extension parts 10 11 When equipping the paver finisher, the following working steps must be carried out: 1. Place extension parts next to the screed on squared timbers. 2. Remove paint and dirt from the contact surfaces between the extension parts and extendable screed parts and mount the extension part.
Page 112 3. Lift the screed and extend; 4. Release quick release couplings (1); push temper deflector plate (2) downwards out of the bottom mounting bracket. 5. Insert extension part mounting screws (4 x (3)) and tighten by hand; 6. Align the extension part with adjusting screws (4) so that it corresponds precisely to the extendable part or extension part.
Page 113: Screed Heater Gas Connections
Screed heater gas connections After the extension parts have been mounted, the connection hoses for the extension parts' burners must be con- nected to the screed's pipe system. - All hoses must be checked for exter- nal damage prior to use and, if any de- fects are found, must be immediately replaced with new hoses.
Page 114: Screed Heater Electrical Connections
Screed heater electrical connections Once extension parts have been fitted, the screed heater's corresponding elec- trical connections must be connected to one another. Each screed section contains a distribu- tor box (1) with the electric heater's inter- nal wiring. - The connection (2) for the supply and control cable to the neighbouring screed section can be found on the upper side of the...
Page 115: Adjusting The Height Of The Extension Parts
Adjusting the height of the extension parts To ensure that the screed lays without marks and the extension parts can also be adjusted to the various operating conditions during use, the height of the extension parts can be adjusted: - Loosen mounting screws (1) - Loosen lock nuts (2) - Set to the desired height using adjust- ing screws (3)
Page 116: Mounting The Material Guide Plates
Mounting the material guide plates - Pre-assemble material guide plates using screws (1); do not tighten screws. - Set material guide plates approx. 1 cm higher than the sliding plates (2): - Set height using adjusting screw (3), then lock with nut (4). - Tighten mounting screws (1).
Page 117: Material Guide Plate Brace
Material guide plate brace E 31...
Page 118: Installing Material Guide Plate Brace
Installing material guide plate brace Depending on the paving width, the material tunnel is braced with brace tube II or with brace tubes I + II. Brace tube II can be inserted into brace tube I in order to extend it. - Mount the front bracket (1) and rear bracket (2) with the relevant assembly parts (3) on the adjustable 1000 mm material tunnel or on the frame of the main screed.
Page 119 When setting the brace tube to compres- sive stress, the spindles on both sides may be unscrewed a maximum of 45 mm! Abstreb_614_615_5.wmf E 33...
Page 120: Settings
Settings Adjusting the tamper height Before each laying operating, check the tamper adjustment. The tamper knives (A) must be located at bottom dead centre flush with the in- clined edges of the sliding plates (B). If correction should be necessary, pro- ceed as follows: Two adjustment points per screed part! EB51_Verstell6.bmp...
Page 121: Adjusting The Tamper Deflector Plate
Adjusting the tamper deflector plate Before each laying operating, check the tamper adjustment. The tamper knife (1) should touch the knife bar ((2) on the screed). The play (a) between the tamper deflec- tor plate (3) and the tamper knife (1) should be 0.5 mm across the entire width.
Page 122: Basic Adjustments
Basic adjustments Prior to basic adjustment, the extendable parts must be adjusted as described in Chapter 5. Carry out basic adjustment as follows: 1. In the case of finishers fitted with tyres, set the correct tyre pressure. 2. Drive the paver finisher onto a level surface. The size of the area must correspond to the total base of the paver finisher.
Page 123 8. Tighten the pointers (3) on the scale on the front of the paver finisher in the bottom position. 9. Retract the levelling cylinders until both pointers are located approx. 1 cm below the zero mark. 10. Loosen the lock nuts (5) at both spin- dles (4) and turn the spindles so that the bolts (6) are stress-free, i.e.
Page 124: Dismantling For Transportation / Special Operating Conditions
Dismantling for transportation / special operating conditions Hinged /pivoting walkway plates The walkway plate is optionally available in the following versions: - Hinged /pivoting walkway plates (A): The individual walkway plates can be pulled from their mounted latch and can be stored in the folded-up position at their support points.
Page 125: F Maintenance
F Maintenance Notes regarding safety Inadvertent starting of the paver finisher can endanger persons working on the screed. Only carry out such work with the paver finisher motor at a standstill unless the instructions state the opposite! Ensure that the paver finisher is secured to prevent unintentional starting. When lifted, the screed can still slide downwards if the mechanical screed transport safeguard is not inserted on the paver finisher.
Page 126: Maintenance Intervals - Screed In General
Maintenance intervals – screed in general Interval Maintenance point Note - Lubricate tamper/vibration bearings - Lubricate tamper bearings of ex- tension parts - Lubricate vibration bearings of ex- tension parts - Lubricate guide tube bearings - Clean / oil guide tubes After work is fin- ished...
Page 127: Maintenance Intervals - Gas System
Maintenance intervals – gas system Interval Maintenance point Note - Check the spark plugs q - Replace the spark plugs - Have gas system checked by an expert Maintenance Maintenance during the running-in period...
Page 128: Maintenance Intervals – Electric Heating System
Maintenance intervals – electric heating system Interval Maintenance point Note - Check insulation monitoring Before start- ing work Note national - Electrical system check by a spe- regulations cialist electrician on checking and inspection inter- vals! Maintenance Maintenance during the running-in period All times given are the maximum permissible maintenance intervals.
Page 129: Lubrication Points
Lubrication points Tamper and vibration bearings With optional operation of a central lubrication system, manual lubrication of the main screed is omitted!
Page 130: Guide Tubes
Guide tubes...
Page 131 To keep the wear and thus the play of the guides as low as possible, any dirt on the guide elements must be removed. Always keep the tubes clean: - After daily work has been terminated, clean the tubes using a piece of cloth and - then slightly oil them.
Page 132: Other Lubricating And Maintenance Points
Other lubricating and maintenance points Grease the chains of the crowning adjuster with a brush or spray-on grease.
Page 133: Checkpoints
Checkpoints Guides of the extendable parts Adjustment of guide tube play - Bush (1) is fixed with nut (2) to the screed. Conical bush (4) can be adjusted with adjusting nut (3). Play-free operation is given at about 90 Nm. The special hook-type wrench in the toolbox must be used.
Page 134: Cleaning The Screed
Cleaning the screed Emptying the tamper compartment F 10...
Page 135: Removing The Tamper Deflector Plates
During operation, bitumen and fine particles enter the tamper frame. Heating keeps them in a plastic state, thus making them available for lubricating the tamper knife. When the screed cools down, these substances solidify. They must be liquefied by heating before the tamper is put into operation again. - Usually, the only cleaning work required at the end of the day is to operate the tamper at slow speed for approx.
Page 136: Hydraulic Hoses
Checking / adjusting the tamper de- flector plate Before each laying operating, check the tamper adjustment. The tamper knife (1) should touch the knife bar ((2) on the screed). The play (a) between the tamper deflec- tor plate (3) and the tamper knife (1) should be 0.5 mm across the entire width.
Page 137: Gas System
Gas system The gas system consists of the following main components: - Ignition burner (1) - Spark plug (2) F 13...
Page 138: Spark Plugs
Spark plugs The spark plugs of the gas heater should be checked once a month: - Pull off the connectors of the spark plugs. - Remove the spark plug insert from the screed body. - Check: - Is there any visible damage to the in- sulator of the centre contact? The correct electrode gap calculated from dimensions A and B is 4 mm!
Page 139: Adjusting The Ignition Burner
Adjusting the ignition burner To ensure proper ignition, the adjusting ring (1) of the ignition burner must be ad- justed. - Loosen the fastening screws of the adjusting ring. - The adjusting ring (1) should cover roughly 50% of the air holes (2). - Tighten the fastening screws of the adjusting ring again.
Page 140: Electric Heating System
Electric heating system Check insulation monitoring The function of the protective insulation monitoring measure must be checked every day before starting work. This check only checks the function of the insulation monitor, not whether an in- sulation error has occurred on the heat- ing sections or consumers.
Page 141: Insulation Faults
Insulation faults If an insulation fault occurs during operation, and the indicator lamp displays an insu- lation fault, the operator may proceed as follows: - Switch the switches of all external equipment and the heating system to OFF and press the reset button for at least 3 seconds to delete the fault. - If the indicator lamp does not go out, the fault lies in the generator.
Page 142 Adjustment process when exchang- ing screed extension cylinder For adjustment purposes, the extenda- ble screed parts are fully extended. The tolerances between the screed and cyl- inder stroke are compensated with the adjusting nut (1) in the plate. The nut rests directly against the piston rod (2).
Page 143: Lubricants
Lubricants Use only the lubricants listed below or comparable qualities of well-known brands. - Dynapac high-temperature grease F 19...
Page 144: Electrical Fuses / Relays
Electrical fuses / relays 10.1 Conventional version, gas heater Fuses in the switch cabinet of the screed heater Fuses Relays F 20...
Page 145: Relay (B)
Fuses (A) Heater ON Ignition box relay Right remote control connection box Left remote control connection box Right/left side board ignition system Left middle section ignition box Right middle section ignition box Left adjustable section ignition box Right adjustable section ignition box Relay (B) Autohold Ignition box...
Page 146: Plc Version, Gas Heater
10.2 PLC version, gas heater Fuses in the switch cabinet of the screed heater Fuses F 22...
Page 147 Fuses (A) Heater control system / screed controller / diagnosis Screed controller output Screed controller output Vibration sensor / tamper sensor Crowning sensor / slope control sensor Heater control system output Left remote control connection box Right remote control connection box Right/left side board ignition system Heater control system output 1 Heater control system output 2...
Page 148: Plc Version, Electric Heater
10.3 PLC version, electric heater Fuses in the terminal box of the screed heater Fuses Fuses (A) Screed controller / diagnosis Screed controller output Screed controller output Vibration sensor / tamper sensor Crowning sensor / slope control sensor Spare Left remote control connection box Right remote control connection box F 24...
Page 149: Fuses In The Control Unit Of The Screed Heater
Fuses in the control unit of the screed heater Fuses Fuses (B) Heater control system Emergency stop F 25...
Page 150 F 26...
Page 151 Parts & Service Training We offer our customers training courses on DYNAPAC equipment in our dedicated factory training centre. We hold regular training courses in this training centre as well as courses outside the scheduled hours. Service Please contact one of our responsible service outlets if you encounter any operational problems or have enquiries about spare parts.
Page 152 www.atlascopco.com...

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Dynapac V5100TV Operation & Maintenance Manual

Preface

A Correct Use and Application

B Description of the Screed

C Transportation

D Operation

E Set-Up and Modification

F Maintenance

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