Dynapac V5100TV Troubleshooting guide

OPERATION & MAINTENANCE
Screed
Dynapac
V5100TV-(E) / V6000TV-(E)
Type 616 / 617
Keep for later use in document compartment
4812038290 (A5) / 4812038295 (A4)
01-0111
Valid for:
_________________ - _________________
_________________ - _________________

www.atlascopco.com

1
Table of contents
V Preface ..................................................................................... 1
1 General safety instructions ........................................................................ 2
1.1 Laws, guidelines, accident prevention regulations ..................................... 2
1.2 Warnings .................................................................................................... 2
1.3 Prohibitive symbols .................................................................................... 4
1.4 Protective equipment ................................................................................. 5
1.5 Environmental protection ........................................................................... 6
1.6 Fire prevention ........................................................................................... 6
1.7 Additional information ................................................................................ 7
2 CE identification and Declaration of Conformity ........................................ 8
3 Guarantee conditions ................................................................................. 8
4 Residual risks ............................................................................................. 9
5 Sensibly predictable incorrect usage ....................................................... 10
A Correct use and application ................................................... 1
B Description of the screed ....................................................... 1
1 Application ................................................................................................. 1
2 Assemblies ................................................................................................. 2
3 Safety ......................................................................................................... 4
3.1 Remaining risks at the screed .................................................................... 4
4 Technical data ............................................................................................ 6
4.1 Dimensions ................................................................................................ 6
4.2 Weights ...................................................................................................... 6
4.3 Adjustment/equipment features ................................................................. 7
4.4 Compacting system ................................................................................... 7
4.5 Gas heater system V 5100 ........................................................................ 8
4.6 Gas heater system V 6000 ........................................................................ 8
4.7 Electric heater V 5100 (o) .......................................................................... 9
4.8 Electric heater V 6000 (o) .......................................................................... 9
5 Location of instruction labels and type plates .......................................... 10
5.1 Warning signs .......................................................................................... 11
5.2 Instructive symbols, prohibitive symbols, warnzeichen ............................ 11
5.3 Further warnings and operating instructions ............................................ 12
5.4 Screed type plate (7) ................................................................................ 13
C Transportation ......................................................................... 1
1 Safety regulations for transportation .......................................................... 1
2 Transporting the removed screed .............................................................. 2
2.1 Transportation by crane ............................................................................. 2
2.2 Transportation by fork-lift truck .................................................................. 2
D Operation ................................................................................. 1

2
1 Notes regarding safety ...............................................................................1
2 Operation of the screed ..............................................................................2
2.1 Extend/retract screed .................................................................................2
2.2 Adjusting the compacting elements - conventional version ........................4
Adjusting the tamper ..............................................................................4
Adjusting the vibration ............................................................................4
2.3 Adjusting the tamper - PLC version ............................................................5
Adjusting the vibration ............................................................................5
3 Operation of the gas heater system with flame monitoring ........................6
3.1 Schematic diagram of the gas supply system ............................................6
3.2 General notes on the gas heater system ...................................................7
3.3 Connection and leak test ............................................................................8
3.4 Commissioning and checking the heater ...................................................9
3.5 Exchanging the gas bottles ......................................................................10
4 Screed heater - conventional version .......................................................11
4.1 Switch cabinet for screed heater ..............................................................11
Ignition process ....................................................................................13
4.2 Function of the flame monitoring system ..................................................14
4.3 Switching off the heater ............................................................................16
5 Screed heater - PLC version ....................................................................17
5.1 Switch cabinet for screed heater ..............................................................17
5.2 Operating the control and monitoring unit ................................................19
Ignition process -
PLC version ..........................................................................................22
5.3 Function of the flame monitoring system ..................................................23
5.4 Temperature display, setting temperature level .......................................25
5.5 Temperature setting .................................................................................25
Energy saving mode / "Energy saving" ................................................26
5.6 Status and error messages ......................................................................27
Emergency programme with sensor error ............................................28
5.7 Switching off the heater ............................................................................29
6 Operating the electric heater ....................................................................30
6.1 Switch cabinet for screed heater ..............................................................30
6.2 Operating the control and monitoring unit ................................................32
6.3 General information on the heating system ..............................................35
Energy saving mode / "Energy saving" ................................................36
6.4 Insulation monitor .....................................................................................37
Insulation faults ....................................................................................38
6.5 Commissioning and checking the heater .................................................39
6.6 Temperature display, setting temperature level .......................................40
6.7 Temperature setting .................................................................................40
6.8 Status and error messages ......................................................................41
Emergency programme with sensor error ............................................42
6.9 Switching off the heater ............................................................................43
7 Malfunctions .............................................................................................44
7.1 Problems during paving ...........................................................................44
7.2 Malfunctions on the screed .....................................................................47
E Set-up and modification .........................................................1

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1 Notes regarding safety ............................................................................... 1
2 Mounting the screed to the paver finisher .................................................. 2
2.1 Mounting the side shields .......................................................................... 3
2.2 Mount side shield, hinged (o) ..................................................................... 4
Installation, hinge ................................................................................... 4
Installation, working position .................................................................. 5
Transport position .................................................................................. 6
2.3 Adjusting the side shield height and support angle .................................... 8
2.4 Mounting the edge compactor ................................................................... 8
2.5 Mounting the cut-off shoe .......................................................................... 9
2.6 Fitting the height sensing device ................................................................ 9
2.7 Adjusting the crowning ............................................................................. 10
2.8 Electrical connections .............................................................................. 11
2.9 Connection for the electric heater (o) ....................................................... 12
3 Screed extension V5100 .......................................................................... 13
3.1 Expansion - extension parts ..................................................................... 13
3.2 Assembly parts - extension parts ............................................................. 14
3.1 Extension - material guide plates V5100 ................................................. 15
3.2 Assembly parts – material guide plates ................................................... 16
4 Screed extension V6000 .......................................................................... 18
4.1 Expansion - extension parts ..................................................................... 18
4.2 Assembly parts - extension parts ............................................................. 19
4.3 Extension - material guide plate V6000 ................................................... 20
4.4 Assembly parts – material guide plates ................................................... 21
5 Adjusting extendable parts ....................................................................... 23
5.1 Setting the height of the extendable parts ............................................... 23
5.2 Adjusting the approach angle of the extendable parts ............................. 24
6 Extending the screed ............................................................................... 25
6.1 Mounting extension parts ......................................................................... 25
6.2 Screed heater gas connections ............................................................... 27
6.3 Screed heater electrical connections ....................................................... 28
6.4 Adjusting the height of the extension parts .............................................. 29
6.5 Mounting the material guide plates .......................................................... 30
6.6 Material guide plate brace ........................................................................ 31
6.7 Installing material guide plate brace ........................................................ 32
6.8 Setting the material tunnel compressive stress ....................................... 32
7 Settings .................................................................................................... 34
7.1 Adjusting the tamper height ..................................................................... 34
7.2 Adjusting the tamper deflector plate ........................................................ 35
7.3 Adjust sliding plates ................................................................................. 35
7.4 Basic adjustments .................................................................................... 36
8 Dismantling for transportation / special operating conditions ................... 38
8.1 Hinged /pivoting walkway plates .............................................................. 38
F Maintenance ............................................................................ 1
1 Notes regarding safety ............................................................................... 1
2 Maintenance intervals – screed in general ................................................ 2
3 Maintenance intervals – gas system .......................................................... 3
4 Maintenance intervals – electric heating system ....................................... 4

4
5 Lubrication points .......................................................................................5
5.1 Tamper and vibration bearings ...................................................................5
5.2 Guide tubes ................................................................................................6
5.3 Other lubricating and maintenance points ..................................................8
6 Checkpoints ................................................................................................9
6.1 Guides of the extendable parts ..................................................................9
Adjustment of guide tube play ................................................................9
6.2 Cleaning the screed .................................................................................10
Emptying the tamper compartment ......................................................10
Removing the tamper deflector plates .................................................11
6.3 Checking / adjusting the tamper deflector plate .......................................12
6.4 Hydraulic hoses .......................................................................................12
7 Gas system ..............................................................................................13
7.1 Spark plugs ..............................................................................................14
7.2 Adjusting the ignition burner .....................................................................15
7.3 Injectors of the gas heater system ...........................................................15
8 Electric heating system ............................................................................16
8.1 Check insulation monitoring .....................................................................16
Insulation faults ....................................................................................17
Adjustment process when exchanging screed extension cylinder .......18
9 Lubricants .................................................................................................19
10 Electrical fuses / relays .............................................................................20
10.1 Conventional version, gas heater .............................................................20
Fuses in the switch cabinet of the screed heater .................................20
Fuses (A) ..............................................................................................21
Relay (B) ..............................................................................................21
10.2 PLC version, gas heater ...........................................................................22
Fuses in the switch cabinet of the screed heater .................................22
Fuses (A) ..............................................................................................23
10.3 PLC version, electric heater .....................................................................24
Fuses in the terminal box of the screed heater ....................................24
Fuses (A) ..............................................................................................24
Fuses in the control unit of the screed heater ......................................25
Fuses (B) ..............................................................................................25

V 1
VPreface
Translation of the original operating instructions.
If the vehicle is to be operated safely, the information provided in these operating in-
structions will be required. The information is provided in a concise, clearly structured
form. The individual chapters are arranged in alphabetical order. and every chapter
starts with page 1. The individual pages are identified by the chapter letter and the
page number.
Example: Page B 2 is the second page of chapter B.
These operating instructions cover various vehicle options. Make sure that during op-
eration and maintenance work the description appropriate to the vehicle option is
used.
In the interest of continued development, the manufacturer reserves the right to make
changes to the vehicle (which will not, however, change the essential features of the
type of vehicle described) without updating the present operating instructions at the
same time.
Dynapac GmbH
Wardenburg
Ammerländer Strasse 93
D-26203 Wardenburg / Germany
Telephone: +49 / (0)4407 / 972-0
Fax: +49 / (0)4407 / 972-228
www.dynapac.com

V 2
1 General safety instructions
1.1 Laws, guidelines, accident prevention regulations
AThe locally applicable laws, guidelines and accident prevention regulations must al-
ways be observed, even if these are not expressly named here.
The user himself/herself is responsible for compliance with the resulting regulations
and measures!
AThe following warnings, prohibitive symbols and instructive symbols indicate dangers
for persons, the vehicle and the environment due to residual risks when operating the
vehicle.
AFailure to observe this information, prohibitions and instructions can result in life-
threatening injuries!
AThe "Guidelines for the Correct Use and Application of Paver Finishers" compiled by
Dynapac must also be observed!

V 3
1.2 Safety signs, signal words
In the safety instructions, the signal words "Danger", "Warning", "Caution", "Note" are
positioned in the coloured title block. They follow a certain hierarchy; in combination
with the warning symbol, they indicate the severity of the danger or the type of note.
"Danger"!
Danger of personal injury.
Indication of an immediately threatening danger that result in fatal or severe injuries
unless the corresponding actions are taken.
"Warning" !
Indication of a possible danger that can result in fatal or se-
vere injuries unless the corresponding actions are taken.
"Caution" !
Indication of a possible danger that result in moderate or mi-
nor injuries unless the corresponding actions are taken.
"Note" !
Indication of a possible drawback unless the corresponding
actions are taken, e.g. unwanted conditions or consequences can occur.
1.3 Other supplementary information
Other information and important explanations are identified by the following picto-
grams:
fPrecedes safety instructions that must be observed in order to prevent danger to per-
sonnel.
mPrecedes notes that must be observed to prevent damage to equipment.
APrecedes general notes and explanations.
DANGER
WARNING
CAUTION
NOTE

V 4
1.4 Warnings
Warning on a dangerous area or hazard!
Failure to observe the warnings can result in life-threatening inju-
ries!
Warning on danger of being pulled in!
mIn this working area/on this element there is a danger of being pulled
in by rotating or conveying elements!
Only carry out activities with elements switched off!
Warning on dangerous electrical voltage!
mAll maintenance and repair work on the screed's electrical system
must always be carried out by an electrician!
Warning on suspended loads!
mNever stand under suspended loads!
Warning on danger of crushing!
mThere is a danger of crushing when certain components are operat-
ed, or certain functions or vehicle movements are carried out.
Always make sure that there are no persons within the endangered
areas!
Warning on hand injuries!
Warning on hot surfaces or hot liquids!

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

V 6
1.5 Prohibitive symbols
Opening/walking on/reaching in/carrying out/setting up are prohibit-
ed during operation or while the drive engine is running!
Do not start engine/drive!
Maintenance and repair work may only be carried out with the diesel
engine shut down!
Spraying with water is prohibited!
Extinguishing with water is prohibited!
Unauthorised maintenance is prohibited!
Only qualified experts may conduct maintenance!
AConsult the Dynapac Service Department
Fire!, naked flames and smoking are prohibited!
Do not switch!

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

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

V 9
1.9 Additional information
mAlso observe the manufacturer's documentation and additional doc-
umentation!
AFor example, the maintenance instructions of the engine manufac-
turer
mDescription / depiction applicable when equipped with gas heater!
mDescription / depiction applicable when equipped with electric heat-
er!
tUsed to indicate standard equipment.
oUsed to indicate optional equipment.

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

V 11
4 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
caused by:
- wrong or improper use of the machine
- defective or missing safety devices
- use of the machine by untrained, uninstructed staff
- defective or damaged parts
- incorrect transport of the machine
- incorrect maintenance or repairs
- leaking operating substances
- emission of noise and vibrations
- impermissible operating substances
Existing residual risks can be avoided by complying and implementing the fol-
lowing:
- warnings at the machine
- warnings and instructions in the safety manual for paver finishers and in the oper-
ating instructions of the paver finisher
- Operating instructions of the machine operator

V 12
5 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
- starting and using the machine outside the operator's platform
- operating the machine with the screed walkway plate hinged up
- failing to comply with the maintenance instructions
- omission or incorrect execution of maintenance or repair work
- spraying the machine with high pressure cleaners

A 1
A Correct use and application
AThe "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.
National regulations are fully applicable.
The road construction machine described in these operating instructions is a paver
finisher that is suited for laying mixed materials, roll-down concrete or lean-mixed
concrete, track-laying ballast and unbound mineral aggregates for foundations for
paving.
The paver finisher must be used, operated and maintained according to the
instructions given in the present operating instructions. Any other use is regarded as
improper use and can cause injury to persons or damage to the paver finisher or other
equipment or property.
Any use going beyond the range of applications described above is regarded as
improper use and is expressly forbidden! Especially in those cases where the paver
finisher is to be operated on inclines or where it is to be used for special purposes
(construction of dumps, dams), it is absolutely necessary to contact the manufacturer.
Duties of the user: A "user" within the meaning of these operating instructions is
defined as any natural or legal person who either uses the paver finisher himself, or
on whose behalf it is used. In special cases (e.g. leasing or renting), the user is
considered to be the person who, in accordance with existing contractual agreements
between the owner and the user of the paver finisher, is charged with the observance
of the operating duties.
The user must ensure that the paver finisher is only used in the stipulated manner and
that all danger to life and limb of the operator, or third parties, is avoided. In addition
to this, it must be ensured that the relevant accident prevention regulations and other
safety-related provisions as well as the operating, servicing and maintenance
guidelines are observed. The user must also ensure that all persons operating the
paver finisher have read and understood the present operating instructions.
Mounting of attachments: The paver finisher must only be operated in conjunction
with screeds that have been approved by the manufacturer. Mounting or installation
of any attachments that will interfere with or supplement the functions of the paver
finisher is permitted only after written approval by the manufacturer has been
obtained. If necessary, the approval of local authorities must be obtained.
Any approval obtained from local authorities does not, however, make approval by
the manufacturer unnecessary.

A 2