Page 1 Instruction Manual Operating and Maintenance Screed - DRV51/DRV60 Serial number: 4200237 - 4812311986_A - EN Dec.2021...
Page 2 www.dynapac.com...
Page 3 Table of contents Preface ..................1 General safety instructions ................ 2 Laws, guidelines, accident prevention regulations ........2 Safety signs, signal words ................. 3 "Danger"! ....................3 "Warning" ! ..................... 3 "Caution" ! ....................3 "Note" ! ....................3 Other supplementary information ............... 3 Warnings ....................
Page 4 Transportation .................1 Safety regulations for transportation ............1 Transporting the removed screed ..............2 Transportation by crane ................3 Transportation by fork-lift truck ..............3 Operation .................1 Notes regarding safety ................1 Operation of the screed ................5 Extend/retract screed .................5 Hydraulic side shields (o) - PLC version ....................7 Adjusting the compacting elements - conventional version ......8 Adjusting the tamper ................8...
Page 5 Emergency programme with sensor error ........... 39 Switching off the heater ................40 Operating the electric screed heater - PLC version ......... 41 Switch cabinet for screed heater .............. 41 Temperature display, setting temperature level ........43 Switching off the heater ................43 Malfunctions .....................
Page 6 Mounting the material guide plates ............35 Material guide plate brace ................36 Installing material guide plate brace ............37 Setting the material tunnel compressive stress ........37 Settings ....................39 Adjusting the tamper height ..............39 Adjusting the tamper deflector plate ............40 Adjust sliding plates ..................40 Basic adjustments ..................41 Dismantling for transportation / special operating conditions ....43 Walkway - removable / hinged ..............43...
Page 7 Relay (B) ....................26 14.2 Conventional version, electric heater ............27 Fuses in the terminal box of the control unit ........27 Fuses (A) --->4812023953 ..............27 Fuses in the control unit of the screed heater ........28 Fuses (B) ..................... 28 Fuses in the extension parts (C) ............
Page 9 V Preface 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.
Page 10 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 11 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 12 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 13 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 14 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 15 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 16 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 17 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 18 - 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 19 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 20 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 21 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 23 B Description of the screed Application The Dynapac DRV51TV / DRV60TV 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 24 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 texture. The tamper and the vibration elements can be individually switched on and off and controlled with regard to speed.
Page 25 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 26 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 27 Danger of burning! Heating the screed heater leads to danger due to hot surfaces, particularly 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 28 Technical data Dimensions DRV51 DRV60 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 modification".
Page 29 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...
Page 30 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 31 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 18000 - 350mm extension part...
Page 32 Location of instruction labels and type plates CAUTION Danger due to missing or misunderstood vehicle signs Missing or misunderstood vehicle signs pose a danger of injuries! - Never remove any warnings or information signs from the vehicle. - Damaged or lost warning or information signs must be replaced immediately.
Page 33 B 11...
Page 34 B 12...
Page 35 Warning signs No. Pictogram Meaning - Warning - Danger of crushing! Crushing points can cause severe or fatal injuries! Maintain a safe distance from the dan- ger area! - Warning - Hot surface - Risk 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 36 Further warnings and operating instructions No. Pictogram Meaning - Attention! Danger due to dangerous electrical volt- age. 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 37 Information signs No. Pictogram Meaning - Operation of the function -On / Off / gas heating side board monitoring -On / Off edge follower -On / Off side board lighting - Operation of the function -On / Off edge follower -On / Off side board lighting - Note interface allocation -Auger limit switches...
Page 38 Screed type plate (20) Item Designation Screed type Maximum operating weight of the screed Screed number Year of construction Manufacturer B 16...
Page 39 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 40 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 41 Transportation by crane WARNING Danger from suspended loads Crane and/or raised vehicle can tilt when lifted and cause severe to fatal injuries! - The vehicle may only be raised at the marked lifting points. - Heed the operating weight of the vehicle. - Do not enter the danger zone.
Page 43 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 secured! - 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 44 Danger due to improper operation DANGER Improper operation of the vehicles can cause severe to fatal injuries! - The vehicle may only be used in the proper manner for i ts intended purpose. - The vehicle may only be operated by trained staff. - The vehicle operators must have made themselves famil- iar with the contents of the operating instructions.
Page 45 Danger of crushing due to moving vehicle parts WARNING Vehicle parts performing movements can cause severe or fatal injuries! - Remaining in the vehicle's danger zone during operation is prohibited! - Do not reach into the danger zone. - Comply with the warning and information signs on the vehi- cle.
Page 46 WARNING Danger from the gas system Incorrectly performed operation and maintenance of the gas system can cause severe or fatal injuries! - Only ever transport full and empty gas bottles with safety caps to protect the bottle valves. - Use the supplied strap retainers to secure gas bottles on the paver finisher to prevent them from turning, tipping over and falling down.
Page 47 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 48 - 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 49 Hydraulic side shields (o) - PLC version Both side shields have an operating unit for hydraulic adjustment. - Raise / lower at front (1) - Front floating position ON / OFF (2) - Upper switch position: ON - Lower switch position: OFF - Raise / lower at rear (3) - Rear floating position ON / OFF (4)
Page 50 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 ro- tary regulator (6).
Page 51 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 52 Additional headlight Side shield (o) - conventional version The side boards are prepared for the connection of additional headlights (1). - Place the magnetic foot of the head- light in the required position and align it accordingly. - Install the corresponding cable prop- erly and put the plug in the corre- sponding socket (2) of the side board.
Page 53 Additional headlight Side shield (o) - PLC version The side boards are prepared for the connection of additional headlights (1). - Place the magnetic foot of the head- light in the required position and align it accordingly. - Install the corresponding cable prop- erly and put the plug in the corre- sponding socket (2) of the side board.
Page 54 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 D 12...
Page 55 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 56 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 57 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 58 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 59 Operating the gas heater - conventional version D 17...
Page 60 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 system. 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 system.
Page 61 Screed gas heater - PLC version D 19...
Page 62 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 20...
Page 63 3.8 Operating the contro l and monitoring unit D 21...
Page 64 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 65 Item Designation / function - "Sensor error" warning lamps Warning lamps 1-4 fo r the individual scr eed sections light up if a defect is present on the corr esponding sensor. Check sensor. The controller oper ates in the emergency programme. - Heater status display Indicator lamps 1-4 for th e individual screed section he aters light up if the corresponding heater circuit is engaged.
Page 66 Ignition process - Conventional control: Actuate the on switch (30) in the switch cabinet: - PLC control: Actuate the on/off switch (50) in the switch cabinet: - 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...
Page 67 3.10 Function of the fl ame monitoring system conventional version Item Designation Left middle se ction malfunction display, red Left extendabl e part malfunction display, red Right middle section ma lfunction display, red Right extendable part malfunction display, red Ignition boxes on the individual screeds Red indicator lamp on the ignition box in t he corresponding screed Yellow indicator lamp on the igni tion box in the corresponding screed D 25...
Page 68 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 69 3.11 Function of the flame monitoring system PLC version 57 56 58 Item Designation Left middle section ma lfunction display, red Left extendable part malfunction display, red Right middle section ma lfunction display, red Right extendable part malfuncti on display, red Ignition boxes on the individual screeds Red indicator lamp on the igni tion box in t he corresponding screed Yellow indicator lamp on the ignition box in the corresponding screed...
Page 70 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 71 3.12 Temperature display, setting temperature level——conventional control - Conventional control: Adjust the screed temperature with regulator (31). The temperature must be coordinated to the paving material and paving situation. - If necessary, readjust the temperature during paving. D 29...
Page 72 3.13 Switching off the heater ——conventional control After work has been completed, or when the heater is no longer required: - Conventional control: Actuate the OFF switch (31) in the switch cabinet: If these valves are not closed, there is a danger of and explosion due to the possible escape of uncombusted gas!
Page 73 3.14 Temperature display, setting temperature level——PLC control 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. 3.15 Temperature setting - Press button (47) or (48) to show the current nominal temperature on the display (52).
Page 74 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 75 3.16 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).
Page 76 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 77 3.17 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 78 3.18 Gas heating side shield (o) - conventional version The side shields have separate flame monitoring separate ON/OFF switching. - Actuate the on/off switch (1) on the in- strument panel; this - opens the electromagnetic non-re- turn valves for the gas supply to the burners;...
Page 79 3.19 Gas heating side shield (o) - PLC version The side shields have separate flame monitoring separate ON/OFF switching. - Actuate the on/off switch (1) on the in- strument panel; this - opens the electromagnetic non-re- turn valves for the gas supply to the burners;...
Page 80 Operation of the electric heater General notes on the electric heating system The electric heating system is supplied with power by a alternator 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 81 Insulation monitor 3 SEC 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 insula- tion error has occurred on the heating sections or consumers. - Start the paver finisher's drive engine.
Page 82 Operating the electric screed heater - PLC version Switch cabinet for screed heater 4 x 230 V 98 99 The configuration of individual elements may vary slightly! D 40...
Page 83 Item Designation OFF button heating Test key for monitoring of insulation and indicator lamp for insulation defects Reset key for insulation monitoring Alternator indicator lamp Not used 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 Heating section 2 indicator lamp...
Page 84 Operating the control and monitoring unit D 42...
Page 85 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 alternator output is insufficient. After switching on, the "Energy saving"...
Page 86 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 87 Commissioning and checking the heater D 45...
Page 88 In order to reach the required temperature, the heater should be switched on approx. 15 - 20 minutes before the start of paving. - Switch on the paver finisher's engine. - Switch on the control and monitoring unit ON / OFF switch (107). - Switch on the ON / OFF switch (83) of the electrically heated side shields (o).
Page 89 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 (104) or (105) to show the current nominal temperature on the dis- play (109).
Page 90 Status and error messages 1010 When an error occurs, the warning lamp (110) 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 (105).
Page 91 Error code Cause of error Measure Error messages without button call-up Warning - Check sensor, the controller lamp (1) - Sensor F1 defective operates in the emergency lights up programme. Warning - Check sensor, the controller lamp (2) - Sensor F2 defective operates in the emergency lights up programme.
Page 92 Switching off the heater After work has been completed, or when the heater is no longer required: - Switch off the ON / OFF switch (83) of the electrically heated side shields (o). - Switch on the control and monitoring unit ON / OFF switch (107).
Page 93 Operating the electric screed heater - convention version Switch cabinet for screed heater 4 x 230 V 98 99 The configuration of individual elements may vary slightly! D 51...
Page 94 Item Designation OFF button heating Test key for monitoring of insulation and indicator lamp for insulation defects Reset key for insulation monitoring Alternator indicator lamp Heating ON/OFF When the heating is switched on, the engine speed is increased to 1,200 rpm Circuit breaker for heating section 1 Circuit breaker for heating section 2 Circuit breaker for heating section 3...
Page 95 Temperature display, setting temperature level The temperature display and the temperature level setting for the screed heating sys- tem is carried out on the control unit of the finisher operating panel. Switching off the heater After work has been completed, or when the heater is no longer required: - Switch off the ON / OFF switch (83) of the electrically heated side shields (o).
Page 96 Malfunctions Problems during paving Problem Cause - 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 - grade control toggles between up and down Wavy surface...
Page 97 Problem Cause - 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 98 Problem Cause - 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 99 Malfunctions on the screed Malfunction Cause Remedy Tamper is obstructed Properly heat the screed by cold bitumen Hydraulic oil level in the tank Top up oil is too low Replace the valve; if neces- Pressure limiting valve sary, repair and adjust the Tamper or vibra- is defective valve...
Page 100 D 58...
Page 101 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 102 Mounting the screed to the paver finisher - Place the screed on a suitable support (squared timber sections, etc.) and back paver finisher 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 103 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 104 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 hinged side shields have been fitted and aligned in the working position to start with!
Page 105 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 106 Transport position...
Page 107 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 108 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 109 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 side shield...
Page 110 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 de- sired crowning is set. - Check the set angle against the scale (3).
Page 111 Electrical connections On the rear wall of the paver finisher: - Plug connector (1) for the electrical consumers on the screed and on the screed heater 's switch cabinet. - Secure the positioned connector using the locking clips on the socket. - PLC electronics: Additionally establish plug connection (2).
Page 112 Electrical connections side board - screed - Conventional version Prepare or make the following electrical connections when the mechanical compo- nents have been mounted and set up: - Set remote control to holder (1). - Connect plug (2) with the remote control. If the remote control is not implemented, the plug (2) has to be set to the bridge socket (2a).
Page 113 Other connection possibilities: - Auger limit switches (5) - Grade control system (6) - External levelling system (7) - 24 volt consumers, e.g. additional lighting (8). When using an external levelling system, this must be logged in using the remote con- trol menu.
Page 114 2.10 Electrical connections side board - screed PLC version Prepare or make the following electrical connections when the mechanical compo- nents have been mounted and set up: - Set remote control on holder (1), tighten knurled screw (1a). - Connect the plug of the lead (2) with the socket (2a) on the remote control. If the remote control is not mounted, the plug has to be set on the bridge socket (3).
Page 115 If the side board is not connected, the socket (5) has to be connected with the bridge plug (5a). Other connection possibilities: - Auger limit switches (6) - Grade control system (7) - External levelling system (8) - 24 volt consumers, e.g. additional lighting (9). When using an external levelling system, this must be logged in using the remote con- trol menu.
Page 116 2.11 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 us- ing the locking clips on the socket. - Insert temperature sensor connec- tors (2).
Page 117 Screed extension DRV51 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 17...
Page 118 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.: 4812045000...
Page 119 Extension - material guide plates DRV51 Material guide plates Brace II required 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 120 Assembly parts - material guide plates Connection Assembly parts for screed / material guide plate (6) - 3 x hex bolts, Art. No.: 0147148503 (6a) - 2 x bolt locking devices, Art. No.: 4749901809 (6b) - 2 x bushes, Art. No.: 4730010815 (6c) - 1 x washer, Art.
Page 121 Assembly description - extension parts, material guide plates, side shields E 21...
Page 122 Screed extension DRV60 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 22...
Page 123 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.: 4812045000...
Page 124 Extension - material guide plate DRV60 Material guide plates Brace II required 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 125 Assembly parts - material guide plates Connection Assembly parts for screed / material guide plate (6) - 3 x hex bolts, Art. No.: 0147148503 (6a) - 2 x bolt locking devices, Art. No.: 4749901809 (6b) - 2 x bushes, Art. No.: 4730010815 (6c) - 1 x washer, Art.
Page 126 Assembly description - extension parts, material guide plates, side shields E 26...
Page 127 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 128 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 129 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 130 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 131 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 132 Connect hydraulic side shields (o) - Connect hydraulic lines (1) with the corresponding connections (1a) of the paver finisher (quick-release cou- pling). Heed the colour markings! Hose routing must be carried out as fol- lows, as otherwise the hoses may be damaged.
Page 133 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 is on the top of the dis- tributor box.
Page 134 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 135 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 136 Material guide plate brace E 36...
Page 137 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 138 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 38...
Page 139 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 140 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 across entire width.
Page 141 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 wheeled finishers, 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 142 7. Tighten the pointers (3) on the scale on the front of the paver finisher in the bottom position. 8. Retract the levelling cylinders until both pointers are located approx. 1 cm below the zero mark. 9. 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 143 Dismantling for transportation / special operating conditions Walkway - removable / hinged - Walkway - removable / hinged: The individual walkway plates can be pulled from their mounted latch and can be stored in the folded-up position at their support points. The hinged walkway plate should only be folded up under the following operating con- ditions: - If the vehicle has to be backed up very closely to a wall or another obstacle.
Page 144 E 44...
Page 145 F Maintenance Notes regarding safety for maintenance DANGER Danger due to incorrect vehicle maintenance Incorrectly performed maintenance and repair work can cause severe or fatal injuries! - Ensure that maintenance and repair work is always only carried out by trained, specialist staff. - All maintenance, repair and cleaning work should only be carried out with the engine turned off.
Page 146 CAUTION Hot surfaces! Surfaces including those behind covering parts, together with combustion gases from the engine or screed heater can be very hot and cause injuries! - Wear your personal safety gear. - Do not touch hot parts of the vehicle. - Only perform maintenance and repair work after the vehicle has cooled down.
Page 147 WARNING Danger from the gas system Incorrectly performed operation and maintenance of the gas system can cause severe or fatal injuries! - Only ever transport full and empty gas bottles with safety caps to protect the bottle valves. - Use the supplied strap retainers to secure gas bottles on the paver finisher to prevent them from turning, tipping over and falling down.
Page 148 Maintenance intervals - screed in general Interval Maintenance point Note - Lubricate the tamper bearing / vibration bearing - Lubricate tamper bearings of extension parts - Lubricate vibration bearings of extension parts - Lubricate guide tube bearings - Clean / oil guide tubes When work is finished - Lubricate crowning adjuster...
Page 149 Maintenance intervals - gas system Interval Maintenance point Note - Check the spark plugs q - Replace the spark plugs q - Adjust ignition burner - Have gas system checked by an expert Maintenance Maintenance during the running-in period...
Page 150 Maintenance intervals - electric heating system Interval Maintenance point Note - Check insulation monitoring Before start- ing work Comply with - Electrical system check by a spe- national cialist electrician regulations for checking and inspection intervals! Maintenance Maintenance during the running-in period All times given are the maximum permissible maintenance intervals.
Page 151 Lubrication points Tamper and vibration bearings With optional operation of a central lubrication system, manual lubrica- tion of the main screed is omitted!
Page 152 Guide tubes...
Page 153 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 154 Other lubricating and maintenance points Grease the chains of the crowning adjuster with a brush or spray-on grease. F 10...
Page 155 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 156 Cleaning the screed Emptying the tamper compartment F 12...
Page 157 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 158 Checking / 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 across entire width.
Page 159 Hydraulic hoses - Specifically check the condition of the hydraulic hoses. - Immediately replace any damaged hoses. Replace hydraulic hoses if the following criteria are found on inspection: - damage of the outer layer to the inlay (e.g. chafing, cuts, cracks). - brittleness of the outer layer (cracking of the hose material).
Page 160 Always comply with the following instructions when installing and removing hydraulic hoses: - Always only use original Dynapac hydraulic hoses! - Always observe high standards of cleanliness! - Hydraulic hoses must always be fitted to ensure that in all operating statuses, - there is no tensile load apart from dead weight.
Page 161 Marking hydraulic hoses / storage period, period of use A number stamped onto the screwed connection provides information about the date of manufacture (A) (month / year) and the maximum pressure per- mitted for this hose (B). Never install hoses on top of one anoth- er and always ensure that they are at the correct pressure.
Page 162 Gas system The gas system consists of the following main components: - Ignition burner (1) - Spark plug (2) F 18...
Page 163 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 insulator of the centre contact? The correct electrode gap calculated from dimensions A and B is 4 mm!
Page 164 Adjusting the ignition burner To ensure proper ignition, the adjusting ring (1) of the ignition burner must be adjusted. - 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 165 Electric heating system Check insulation monitoring 3 SEC 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 insula- tion error has occurred on the heating sections or consumers. - Start the paver finisher's drive engine.
Page 166 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 cylinder stroke are compensated with the adjusting nut (1) in the plate. The nut rests directly against the piston rod (2).
Page 167 General visual inspection A walk around the screed with the following inspections form part of the daily routine: - Are components or controls damaged? - Are there leaks from the hydraulic components, etc.? - All fastening points OK? - Are the warnings affixed to the vehicle complete and legible? - Are the non-slip surfaces at ladders, steps, etc.
Page 168 Lubricants 13.1 Grease Dynapac Paver Grease is recommended F 24...
Page 169 Electrical fuses / relays 14.1 Conventional version, gas heater 9 10 11 12 13 Fuses in the switch cabinet of the screed heater Fuses Relays F 25...
Page 170 Fuses (A) Function Heating ON / flame monitoring Right/left side board ignition system / ignition box relay Connection box - right remote control Connection box - left remote control / screed illumination Left middle section ignition box Right middle section ignition box Left adjustable section ignition box Right adjustable section ignition box Relay (B)
Page 171 14.2 Conventional version, electric heater Fuses in the terminal box of the control unit Fuses Fuses (A) --->4812023953 Function Spare Spare Connection box - right remote control Connection box - left remote control / screed illumination F 27...
Page 172 Fuses in the control unit of the screed heater Fuses Fuses (B) Function Heater control system Heater OFF Alternator watchdog 2,5F F 28...
Page 173 Fuses in the extension parts (C) Function Heater section 3 / extension part 750mm Heater section 3 / extension part 350mm Heater section 4 / extension part 750mm Heater section 4 / extension part 350mm F 29...
Page 174 14.1 PLC version, gas heater 14.2 Fuses All fuses for the screed are in the terminal box of the paver finisher! See operating instructions for the paver finisher. 14.3 Relays Relays Function Switchgear heater section, left main screed Switchgear heater section, right main screed Switchgear heater section, left extendable part Switchgear heater section, right extendable part F 30...
Page 175 14.1 PLC version, electric heater 14.2 Fuses Fuses in the control unit of the screed heater Fuses Fuses (B) Function Alternator watchdog 2,5F Other fuses for the screed are in the terminal box of the paver finisher! See operating instructions for the paver finisher. F 31...
Page 176 Fuses in the extension parts (C) Function Heater section 3 / extension part 750mm Heater section 3 / extension part 350mm Heater section 4 / extension part 750mm Heater section 4 / extension part 350mm F 32...
Page 177 Bolts - torques 15.1 Standard metric threads - strength class 8.8 / 10.9 / 12.9 dry / lightly oiled Molykote ® 10.9 10.9 12.9 12.9 10.9 10.9 12.9 12.9 1020 1206 1410 1067 1281 1200 1622 1948 1049 1475 1770 1581 2224 2669...
Page 178 15.2 Fine metric threads - strength class 8.8 / 10.9 / 12.9 dry / lightly oiled Molykote ® 10.9 10.9 12.9 12.9 10.9 10.9 12.9 12.9 M3x0,35 M4x0,5 M5x0,5 M6x0,75 12,9 15,5 11,6 13,9 M8x1 21,7 30,6 36,7 19,5 27,4 32,8 M10x1,25 42,1...
Page 179 Preserving the screed 16.1 Shutdowns for up to 6 months - Park the vehicle in a place where it is protected from great exposure to direct sun- light, wind, humidity and frost. - Grease all lube points in accordance with specifications. Let any optional central lubricating unit run (paver finisher).
Page 180 Disposal A suitably authorised company must be contracted to dispose of components and op- erating materials and to dismantle the machine in the event of disposal. 17.1 Disposal measures Correctly sorted disposal must be carried out after replacing wear and spare parts and after the vehicle has been withdrawn from service (scrapped).
Page 181 Dynapac (China) Compaction & Paving Equipment Co., Ltd. Tianjin, China.

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