ABG 225-325

Ref. No. VOE21A1004217 CPN 80846710 Printed in Sweden 2008-05 Volvo, Hameln

English CST

California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

California Proposition 65 Warning Battery posts, terminals and other related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and other reproductive harm. Wash hands after handling.

Table of Contents INTRODUCTION PROCEDURE WHEN RECEIVING THE MACHINE ..................................................................... 0-3 DATA REQUIRED FOR ORDERING SPARE PARTS................................................................... 0-3 MACHINE IDENTIFICATION PLATE ....................................................................................... 0-3 ENGINE IDENTIFICATION PLATE .......................................................................................... 0-4 SAFEKEEPING THE OPERATING MANUAL AND FIRST AID BOX ............................................. 0-4

SAFETY EXPLANATION OF THE SAFETY SYMBOLS ........................................................................... 1-2 IMPORTANT GENERAL INFORMATION .................................................................................. 1-3 INTENDED AND UNINTENDED USE ...................................................................................... 1-4 INTENDED USE ........................................................................................................... 1-4 UNINTENDED USE....................................................................................................... 1-4 RESPONSIBILITIES OF THE USER / CONTRACTOR ................................................................. 1-5 RESPONSIBILITIES OF THE PERSONNEL .............................................................................. 1-7 INSTRUCTIONS FOR SPECIAL HAZARDS .............................................................................. 1-8 PRECAUTIONS FOR HANDLING HAZARDOUS GOODS ..................................................... 1-8 PRECAUTIONS WHEN HANDLING GAS HEATING SYSTEMS ........................................... 1-10 GAS HOSE ROUTING ......................................................................................... 1-12 SAFETY PRECAUTIONS WHEN GAS ESCAPES .............................................................. 1-13 SAFETY PRECAUTIONS WHEN THE MACHINE TOUCHES LIVE ELECTRIC CABLES ............. 1-14

INSTRUMENTS AND CONTROLS MACHINE OVERVIEW ......................................................................................................... 2-3 OPERATOR'S PLATFORM ................................................................................................... 2-4 OPERATOR'S SEAT............................................................................................................ 2-5 STANDARD SEAT ........................................................................................................ 2-5 DELUXE SEAT ............................................................................................................ 2-6 CONTROL PANEL .............................................................................................................. 2-7 EXTERNAL CONTROL PANELS .......................................................................................... 2-20 STORAGE COMPARTMENTS ............................................................................................. 2-22 FUEL TANK ..................................................................................................................... 2-23 CENTRAL LUBRICATION SYSTEM (OPTION)....................................................................... 2-24 MAT THICKNESS SCALES ................................................................................................. 2-25 EMULSION SPRAYING SYSTEM (OPTION).......................................................................... 2-26 POTENTIOMETERS FOR VIBRATORS AND TAMPERS ........................................................... 2-27 SWITCH OFF THE LEVELLING CYLINDERS IN CASE OF BREAKDOWNS ................................. 2-28 SCREED HEATING SYSTEM (OPTION)............................................................................... 2-30 ELECTRONIC LEVELLING SYSTEM (OPTION) ..................................................................... 2-32 ELECTRICS ..................................................................................................................... 2-33 BATTERY MASTER SWITCH ....................................................................................... 2-33 WORKING LIGHTS ..................................................................................................... 2-34 SOCKETS / FUSES ON THE PAVER'S LH REAR WALL.................................................. 2-35 SOCKETS ON THE PAVER'S RH REAR WALL .............................................................. 2-36 SOCKETS ON THE LH AND RH EXTERNAL CONTROL PANELS ..................................... 2-37 SWITCH CABINET ON THE OPERATOR'S PLATFORM .................................................... 2-38 SWITCH CABINET ON THE PAVER'S REAR WALL......................................................... 2-39 SOCKETS ON THE PAVER'S REAR WALL .................................................................... 2-40

Track Paver Titan 225/325

Ref. No. VOE21A1004217

1

Table of Contents OPERATION IMPORTANT INSTRUCTIONS FOR OPERATION .......................................................................3-3 APPLICATION SPECIFIC SAFETY INSTRUCTIONS ...................................................................3-4 PAVING IN TUNNELS ....................................................................................................3-4 PAVING IN THE VICINITY OF OVERHEAD ELECTRIC CABLES .............................................3-4 PAVING IN CONTAMINATED AREAS ................................................................................3-4 PAVING IN THE VICINITY OF RAILWAY LINES ...................................................................3-4 PAVING ON SLOPES .....................................................................................................3-5 PAVING ON BRIDGES....................................................................................................3-5 COMMISSIONING THE PAVER ..............................................................................................3-6 CHECK BEFORE COMMISSIONING THE PAVER ...............................................................3-6 SWITCHING THE POWER SUPPLY ON AND OFF............................................................3-7 SETTING UP THE OPERATOR'S PLATFORM ....................................................................3-8 RAISING AND LOWERING THE SUN ROOF ..............................................................3-9 EXHAUST PIPE, FITTING AND REMOVING .............................................................3-11 FITTING THE SIDE CURTAINS ..............................................................................3-12 WINDSCREEN (OPTION), RAISING AND LOWERING ...............................................3-13 OPERATOR'S PLATFORM, EXTENDING AND RETRACTING ......................................3-14 SEAT CONSOLE, EXTENDING AND RETRACTING ...................................................3-15 CONTROL COLUMN, CROSS SLIDING ...................................................................3-16 OPERATOR'S SEAT, ADJUSTING (STANDARD SEAT) .............................................3-17 OPERATOR'S SEAT, ADJUSTING (DELUXE SEAT) .................................................3-18 STARTING THE ENGINE ..............................................................................................3-19 STARTING THE ENGINE WITH THE STARTER BATTERIES .......................................3-20 JUMP STARTING THE ENGINE .............................................................................3-21 STOPPING THE ENGINE..............................................................................................3-23 STARTING AND STOPPING THE PAVER ..............................................................................3-24 DRIVING THE PAVER ON ROADS AND JOB-SITES .........................................................3-25 TURNING ON-THE-SPOT) ............................................................................................3-27 OPERATING THE PAVER IN AUXILIARY CONTROL (EMERGENCY CONTROL) ...................3-28 STARTING THE PAVER ........................................................................................3-28 STOPPING THE PAVER ........................................................................................3-28 PREPARING THE PAVER FOR OPERATION ..........................................................................3-29 REFUELLING THE PAVER............................................................................................3-30 LUBRICATING THE PAVER ...........................................................................................3-32 FRONT CROSS BEAM ................................................................................................3-34 ROAD SCRAPERS, RAISING AND LOWERING................................................................3-35 LOWERING THE ROAD SCRAPERS .......................................................................3-35 RAISING THE ROAD SCRAPERS ...........................................................................3-35 ADJUSTING THE ROAD SCRAPERS ......................................................................3-35 HOPPER WINGS, OPEN AND CLOSE ...........................................................................3-36 HOPPER WINGS, OPEN AND CLOSE ....................................................................3-36 SCREED TRANSPORT LOCK .......................................................................................3-36 RAISING AND SECURING THE SCREED IN THE TRANSPORT LOCK..........................3-38 RELEASING AND LOWERING THE SCREED FROM THE TRANSPORT LOCK ...............3-38 VARIOMATIC SCREED, EXTEND AND RETRACT ............................................................3-39 SCREED TENSIONING DEVICE, ASSEMBLING AND DISMANTLING ...................................3-40 SCREED SPACER BLOCKS (OPTION) ..........................................................................3-42 FITTING THE SCREED SPACER BLOCKS ...............................................................3-42 REMOVING THE SCREED SPACER BLOCKS ..........................................................3-42 AUGER HEIGHT ADJUSTMENT ....................................................................................3-42 ADJUSTING THE HEIGHT OF THE BASIC AUGERS..................................................3-44 ADJUSTING THE HEIGHT OF THE AUGERS WITH OUTER BEARINGS .......................3-45 FITTING AUGER EXTENSIONS .....................................................................................3-46 AUGER CONTROL, ADJUSTING ...................................................................................3-49

2


Table of Contents ADJUSTING THE CONVEYOR CONTROL (PADDLE TYPE CONTROL SWITCHES) ............... 3-50 TOO MUCH MATERIAL IN THE AUGER CHANNEL .................................................... 3-50 NOT ENOUGH MATERIAL IN THE AUGER CHANNEL ................................................ 3-50 DIRECTION INDICATOR, SETTING UP .......................................................................... 3-51 ELECTRONIC LEVELLING SYSTEM .............................................................................. 3-51 PAVING .......................................................................................................................... 3-52 SETTING THE OPERATING MODE AUTOMATIC ............................................................ 3-52 MAT THICKNESS, ADJUSTING .................................................................................... 3-53 SCREED FLOATING MODE ......................................................................................... 3-54 SCREED HEATING, ON / OFF ................................................................................... 3-56 PAVING IN THE AUTOMATIC MODE ............................................................................. 3-57 PAVING MATERIAL PRONE TO SEGREGATION ....................................................... 3-58 MAT THICKNESS IS NOT CORRECT ...................................................................... 3-58 TOW POINT SINKS DOWN DURING PAVING WORK ................................................. 3-59 CONVEYING THE PAVING MIX TO ONE SIDE .......................................................... 3-59 PAVING MATERIAL NOT CONVEYED FAST ENOUGH ............................................... 3-60 SETTING THE PRESSURE ON THE SCREED ASSIST ............................................... 3-60 DAILY PROCEDURE AT THE END OF PAVING WORK ............................................................ 3-61 LOADING AND TRANSPORT .............................................................................................. 3-62 LOADING BY CRANE.................................................................................................. 3-62 LOADING ON A VEHICLE WITH RAMPS ........................................................................ 3-65 LASHING THE MACHINE ON THE VEHICLE ................................................................... 3-66

MAINTENANCE IMPORTANT INSTRUCTIONS ................................................................................................ 4-2 BEFORE STARTING MAINTENANCE WORK .................................................................... 4-5 HANDLING HAZARDOUS MATERIALS ............................................................................ 4-6 WELDING WORK ON THE PAVER ................................................................................. 4-6 FIRST OIL CHANGE..................................................................................................... 4-6 MAINTENANCE CHART ....................................................................................................... 4-7 MAINTENANCE WORK ...................................................................................................... 4-10 MACHINE (GENERAL) ................................................................................................ 4-10 CLEANING THE MACHINE ................................................................................... 4-10 TIGHTEN THREADED CONNECTIONS .................................................................... 4-10 DIESEL ENGINE ........................................................................................................ 4-11 CHECK THE ENGINE OIL LEVEL ........................................................................... 4-11 FUEL FILTER - DRAINING OFF THE WATER ........................................................... 4-12 ELECTRICAL SYSTEM ................................................................................................ 4-13 CHARGE THE BATTERY ...................................................................................... 4-14 GREASING THE BATTERY TERMINALS .................................................................. 4-14 HYDROSTATIC SYSTEM ............................................................................................. 4-15 HIGH PRESSURE FILTER FOR THE LEVELLING CYLINDERS AND AUGERS .............. 4-16 FEED PRESSURE FILTER FOR THE TRAVEL DRIVE AND TAMPER DRIVE (ONLY FOR VDT AND VDT-V SCREEDS) ........................................................... 4-17 CLEANING THE VENT FILTER .............................................................................. 4-18 CLEANING THE HYDRAULIC OIL COOLER AND RADIATOR ..................................... 4-19 TRANSMISSION GEARS ............................................................................................. 4-20 CHECK THE PUMP DISTRIBUTOR GEAR ................................................................ 4-20 CHECK THE TRAVEL DRIVE TRANSMISSIONS ........................................................ 4-20


3

Table of Contents DRIVE CHAINS AND V-BELTS ......................................................................................4-21 V-BELTS ............................................................................................................4-22 DRIVE CHAINS ....................................................................................................4-23 TENSIONING THE CONVEYORS ............................................................................4-24 AUGER CENTRE DRIVE.......................................................................................4-25 AUGER OUTER DRIVES ......................................................................................4-26 PRESERVATION FOR LONGER PERIODS OF STANDSTILL .....................................................4-27 LUBRICATION PLAN ..........................................................................................................4-28 GREASE POINTS .......................................................................................................4-29 CENTRAL LUBRICATION SYSTEM (OPTION) .................................................................4-32 OIL CHANGE, TRANSMISSION GEARS .........................................................................4-33 OIL CHANGE, PUMP DISTRIBUTOR GEAR....................................................................4-34 OIL CHANGE, HYDRAULIC SYSTEM .............................................................................4-36 OIL CHANGE, DIESEL ENGINE ....................................................................................4-38

TROUBLE SHOOTING TROUBLE SHOOTING ...................................................................................................5-3 FUSES AND RELAYS ...........................................................................................................5-6 TOWING THE PAVER ..........................................................................................................5-7 MANUALLY RELEASING THE PARKING BRAKE .................................................................5-8 RELEASING THE HYDRAULIC DRIVE MOTORS TO RUN FREELY ......................................5-9 REMOVING PAVING MATERIAL FROM THE AUGER CHANNEL ........................................5-10

TECHNICAL DATA TITAN 225 .........................................................................................................................6-2 GENERAL DATA ...........................................................................................................6-2 NOISE AND VIBRATION VALUES ....................................................................................6-4 DIMENSIONS ...............................................................................................................6-5 TITAN 325 .........................................................................................................................6-6 GENERAL DATA ...........................................................................................................6-6 NOISE AND VIBRATION VALUES ....................................................................................6-8 DIMENSIONS ...............................................................................................................6-9

CONSUMABLES LIST OF FUEL OILS AND LUBRICANTS..................................................................................7-3

TORQUES FOR THREADED CONNECTIONS TABLE OF TORQUES - ISO ................................................................................................8-2

GLOSSARY OF TERMS ALPHABETICAL INDEX .........................................................................................................9-II

4


INTRODUCTION


0-1

INTRODUCTION

INTRODUCTION This operating manual provides the operators and maintenance personnel on the job-site with vital instructions, rules and criteria for operating and servicing the track paver model Titan 225/ 325. The operator must carefully read and understand the operating and maintenance manual before operating the machine. The operating manual contains the following chapters: •

INTRODUCTION

•

Chapter 1, SAFETY

•

Chapter 2, INSTRUMENTS AND OPERATING CONTROLS

•

Chapter 3, OPERATING INSTRUCTIONS

•

Chapter 4, MAINTENANCE

•

Chapter 5, TROUBLE SHOOTING

•

Chapter 6, TECHNICAL SPECIFICATION

•

Chapter 7, FUEL AND LUBRICANT SPECIFICATIONS

•

Chapter 8, TORQUE SPECIFICATIONS

If any part of this manual cannot be understood, contact your supervisor or local distributor. The operators and maintenance personnel must understand the instructions contained in this manual. This is an essential condition for working safely with the machine. The correct machine operation, use and regular maintenance are also essential elements to provide the highest performance and safety. Remarks:No part of this operating manual may be reproduced, stored in electrical data systems, processed, copied or published in any way without prior written approval by the manufacturer. All rights for copying, distribution and translation are reserved by the manufacturer. Remarks:Machines may be illustrated in this manual equipped with accessories.

0-2


INTRODUCTION

PROCEDURE WHEN RECEIVING THE MACHINE Your machine has been tested, accurately checked and prepared for shipment before leaving the factory. Upon receipt, check the machine for transport damage and missing parts.Use the shipping documents sent with the machine and your purchase order to make a complete check of the equipment. Immediately inform the carrier if the machine is damaged or any parts are missing.He will tell you what to do in cases of a claim.

DATA REQUIRED FOR ORDERING SPARE PARTS An exact description of the model and serial number of your machine will facilitate a fast and efficient response from our spare parts and service departments. Always have the model and serial number of your machine close at hand when contacting your local spare parts and service organisation. We advise you to enter your machine data in the following lines so that they are always available when required: Model ....................................... Serial No. ................................. Year of manufacture................. Engine Serial No. and type of engine.........................................

MACHINE IDENTIFICATION PLATE The machine's identification plate (1) is located on the RH side of the machine at the rear of the cover plate. Illustration 1: Machine Identification Plate


0-3

INTRODUCTION

ENGINE IDENTIFICATION PLATE The engine serial number is marked on the engine's identification plate (2). Illustration 2: Engine Identification Plate

SAFEKEEPING THE OPERATING MANUAL AND FIRST AID BOX Safely store the operating manual for the paver, the screed, the engine and for other options in the storage compartment (3) for the first aid box. Renew any documents if they have become illegible. Remarks:Ensure the first aid box is always stored in this storage compartment.The contents of the first aid box must be complete and in a perfect condition. Regularly check the first aid box and renew any missing or outdated items. Illustration 3: Storage compartment for the first aid box and documentation

0-4


CHAPTER1- SAFETY


1-1

Chapter 1

SAFETY

SAFETY Closely observe the recommended precautions and instructions for safely operating the machine.

EXPLANATION OF THE SAFETY SYMBOLS Safety symbols used in this manual. They indicate a potential danger. Closely observe all safety symbols to avoid fatal accidents, injuries and damage to property and the environment.

!

DANGER (Red background)

!

WARNING

The safety symbol "DANGER" indicates a specially dangerous situation. Fatal accidents or serious injuries will occur if this symbol is not observed. The safety symbol "WARNING" indicates a potentially dangerous situation. Fatal accidents or serious injuries CAN occur if this symbol is not observed.

(Orange background)

!

CAUTION

(Yellow background)

NOTICE

The safety symbol "CAUTION" indicates a potentially dangerous situation. Minor or medium injuries or damage to the environment CAN occur if this symbol is not observed. The safety symbol "NOTICE" draws attention to special assembly, operating or maintenance instructions not directly connected with danger.

(Blue background) REMARKS: Remarks contain information for the efficient application of the machine. PLEASE NOTE: Contains general information not connected with danger.

1-2


SAFETY

Chapter 1

IMPORTANT GENERAL INFORMATION Closely observe the following before operating or servicing the machine: •

The manufacturer cannot predict all potential hazards which can expose personnel to danger. The warning symbols in this manual and the warning symbols on the machine cannot advert all potential hazards.

•

The machine has been designed and manufactured in accordance with the current norms, standards and recognised safety regulations. In spite of this, improper use can lead to serious injury or even death of the operator or other persons. Damage may also occur on the machine, to property and the environment.

•

All locally prevailing accident prevention regulations, directives and laws must be strictly observed. These still apply although they are not specifically mentioned in this manual. The user is solely responsible for ensuring these regulations, directives and laws are strictly complied with.


1-3

Chapter 1

SAFETY

INTENDED AND UNINTENDED USE INTENDED USE The Titan paver has been designed for paving all kinds of asphalt materials, cement treated aggregates, graded aggregates, sand and gravel which are paved to generally recognized standards. Other materials should not be paved with the paver. The paver may only be operated on a specially prepared surface with sufficient bearing capacity. Adhere to all application conditions specified.The specified maximum slope (< 25 %) must be maintained without fail. The machine must be secured by a suitable means if your paving project requires a special paver application.The surface must be firm with sufficient bearing capacity when operating on special paver applications. Before using the machine for special applications, obtain information from the manufacturer on its ability to perform such work. All functional faults, especially those which effect the safety of the machine, must be immediately rectified.We recommend the exclusive use of genuine accessories and spare parts. We cannot ensure the suitability and quality of other parts and cannot accept any liability for damage and accidents resulting from the use of such parts. Intended use also includes closely observing the operating instructions and adhering to the service and maintenance intervals.

UNINTENDED USE The manufacturer accepts no liability whatsoever for damage caused by unintended use. The risks arising from an unintended use of the machine are borne entirely by the user. Unintended use of the machine includes: •

Transporting loads.

•

Towing or recovering other vehicles.

•

For compacting on hard bases (e.g. concrete or frozen soil).

•

Operating the machine in areas where there is a danger of an explosion.

•

Operating the machine in public traffic.

•

Operating the machine in closed or poorly ventilated areas. Remarks: There is no warranty for the safe operation of the paver if it is put to unintended use. The manufacturer does not accept any liability whatsoever for personal injury or damage to property if the machine is put to an unintended use.

1-4


SAFETY

Chapter 1

RESPONSIBILITIES OF THE USER / CONTRACTOR The paver can only operate safely on the job-site if all necessary safety measures have been taken. It is the responsibility of the user/contractor to plan implement all necessary safety measures and ensure they are strictly observed. As the user / contractor please ensure that: •

The machine is only operated for its intended use.

•

The machine is only used in a perfect functional and operating condition and with all safety devices supplied with the machine.

•

All maintenance and service intervals are strictly adhered to. The correct function of all safety devices must be regularly checked.

•

Only fully qualified persons carry out work on the machine. The personnel assigned to work on the machine must be suitably trained and have adequate experience in handling such equipment and qualified for performing the respective work. The manufacturer offers suitable training courses for the personnel.

•

Any work on the machine's electrical system and equipment may only be performed by a trained assistant electrician or a similarly trained person whereby they are supervised and controlled by a fully trained and qualified electrician. This work must be carried out in accordance with your locally prevailing electro-technical regulations and directives.

•

Ensure that the gas heating system is operated and maintained by fully qualified and authorized personnel who have been thoroughly instructed in the operation and maintenance of the system and from whom it is expected that they will carry out the work in a reliable manner.

•

Work on the machine's chassis, the brakes, the hydraulics and the steering system may only be carried out by fully qualified personnel who have been appropriately trained and have the required skills.

•

The personnel must be regularly trained in all matters of occupational health and safety as well as environment protection. The personnel must be aware of and observe all regulations concerning hazardous goods and materials. All locally prevailing laws and regulations must be complied with.

•

The personnel must be told to read the operating manual and especially the safety instructions included in the manual.It is the owner's / contractor's responsibility to ensure his personnel has read and understood the operating manual.

•

The documentation is safely stored in the compartment provided on the machine. The documentation must always be close at hand on the machine. The operating instructions must be supplemented by detailed working instructions appropriate to the individual job-site.

•

The required protective clothing must be made available to the personnel for operating, servicing and repairing the machine. The personnel must be instructed to wear protective clothing at all times.All necessary safety precautions must be taken on the job-site.


1-5

Chapter 1 •

1-6

SAFETY The contractor / owner must clearly delegate responsibilities to his personnel for setting up, operating, servicing and repairing the machine. The operator must be authorised to reject instructions from third persons which may jeopardise safety.


SAFETY

Chapter 1

RESPONSIBILITIES OF THE PERSONNEL All personnel must ensure the following: •

Thoroughly read the operating manual.You must be able to operate the machine safely and know and understand all procedures for safely carrying out maintenance work.

•

Always take the prescribed safety precautions and wear protective clothing for your personal protection.

•

Operators and maintenance personnel must exercise extreme caution and foresight when performing work to recognise potential hazards.

•

Operators with long hair must tie it into a bun or wear a protective helmet; wear overalls that fit snug to the body and remove all rings and jewellery.Loose overalls, long hair and jewellery may become entangled in the machine. This can lead to serious injuries and fatal accidents.

•

Contact your supervisor or your nearest authorised distributor if you have any questions concerning the safe handling and maintenance of your machine. NEVER WORK ON AN ASSUMPTION, carry out an inspection.

•

The machine is only used in a perfect functional and operating condition and with all safety devices supplied with the machine.

•

Immediately stop the machine if a functional fault occurs. The faulty function must be immediately reported to your supervisor / responsible department.

•

Never perform maintenance work when the engine is running and the hydraulics are under pressure. Before starting any work on the machine, ensure it cannot be switched on, secure it against rolling off and lower the screed.

•

Modifications or alterations affecting the safety of the machine may not be carried out without prior approval by the manufacturer. This applies to the installation and adjustment of safety devices and valves as well as welding work on load bearing assemblies and elements.

•

Always adhere to the specified intervals for service and maintenance work.

•

Avoid a risky manner of driving and operation.


1-7

Chapter 1

SAFETY

INSTRUCTIONS FOR SPECIAL HAZARDS PRECAUTIONS FOR HANDLING HAZARDOUS GOODS The following information provides instructions for the correct handling of hazardous materials from machines. Further information can be obtained from your nearest distributor.

!

CAUTION

The following emission will be a health hazard if not properly handled (refer to Table1). Table 1: Precautions for Handling Hazardous Materials Emission

Precaution

Engine exhaust

Do not inhale. Avoid an accumulation of exhaust fumes in closed rooms.

Particles of dust from an electric motor / generator (brushes / insulation)

Avoid inhaling dust particles during maintenance work.

!

CAUTION

The following emission will be a health hazard if not properly handled (refer to Table2). Table 2: Precautions for Handling Hazardous Goods Material

1-8

Precaution

Anti-freeze solution (water cooled engine)

Avoid inhaling, swallowing and skin contact; do not allow to penetrate the environment.

Hydraulic oil


Engine oil


Grease


Corrosion protection



SAFETY

Chapter 1

Material

Precaution

Fuel

Avoid inhaling, swallowing and skin contact; do not allow to penetrate the environment. Fuel is highly inflammable;when handling fuel, ensure there are no sparks or naked flames in the far-reaching surroundings. Do not smoke when refuelling.

Battery water


Gear oil



1-9

Chapter 1

SAFETY

PRECAUTIONS WHEN HANDLING GAS HEATING SYSTEMS This chapter contains important instructions for the gas heating system on the paving screed if your paver is equipped with this option.

!

DANGER

Liquid gas is highly inflammable and burns explosively.Liquid gas is heavier than oxygen, it sinks to the ground and displaces the oxygen. This results in a danger of suffocation. Closely observe the following safety instructions to avoid serious injury and damage to property. •

The gas heating system may only be operated and serviced by qualified and authorised personnel who have been specially trained in the operation and maintenance of such systems.

•

Ensure the complete gas heating system is checked by a fully qualified and authorized person as follows: — Before using the gas heating system for the first time, ensure that it is correctly installed and has no gas leaks. — Check the working safety of the system on completion of all maintenance and repair work. — Check the working condition, function, installation and gas leaks in the system if it has been out of operation for more than one year.

1-10

•

Your locally prevailing regulations for checking gas bottles still apply and are not effected by this chapter.

•

All gas connections must be checked for leakage and damage.Only use gas detectors approved for gas systems.Searching for gas leaks with a naked flame is a deadly peril and listening for escaping gas is not a safe method either. Do not use the gas heating system if the hoses or connections are porous or damaged.

•

Only operate the gas heating system in open and well ventilated areas.

•

Protect the gas heating system from direct sun rays and other sources of heat (max. 50 °C). Cover the gas bottles with the canopies supplied with the paver.

•

Close the valves on the gas bottles by turning them clockwise when the gas heating system is not in use, e.g. during breaks in paving and when working on the system. Disconnect, remove and properly store the gas bottles during longer standstill times.

•

The gas heating system must be switched off during cleaning work.


SAFETY

Chapter 1 •

When performing any work on the gas heating system, ensure there are no sources of ignition within a radius of 10 metres.Do not smoke, do not ignite any naked flames and do not switch on any electrical appliances within this safety radius (danger of flashover).

•

Safely mount the gas bottles on the paver using the supports and brackets provided and ensure they are secured against rotating or falling over. Only withdraw gas from the bottles when they are in an upright position.

•

During operation, the gas bottles should not be allowed to become under-cooled as this may cause an interruption in the flow of gas. Icing on the bottles caused by an exceptionally high withdrawal of gas must be allowed to thaw off using warm air or warm water with a temperature not exceeding 50°[C]. Never use a naked flame, red hot objects or convector heaters to thaw off the gas bottles. Icing must not be hammered off the gas bottles or removed mechanically in a similar manner.

•

When replacing hoses, ensure the new hoses and connections are suitable for gas heating systems and are routed in such a way to protect them from chemical, thermal and mechanical damage.

•

The gas heating system may only be operated using a pressure control valve with integrated leak tester and hose rupture safety control.

•

Leaky gas bottles must be immediately removed from the danger zone, if this is possible without submitting yourself to danger and be appropriately marked.

•

Never operate the gas heating without the ventilation system correctly installed and keep the ventilation intake and outlet apertures free from blockages to ensure an adequate natural ventilation.

•

Fire and explosion precautions must be taken if the heating system is operated in buildings or areas where explosive gases can be reckoned with. Keep all combustible objects and cleaning cloths which may ignite away from hot parts on the heating system.

•

Parts in the heating system which are subject to wear and deterioration must be renewed after 8 years at the latest. An exception to this rule is when a specialist confirms their perfect working condition.

•

In case of fire, remove the gas bottles to a safe area and keep them cool but do not subject yourself to danger.

•

Store the gas bottles correctly: — Fit the cap nut and protective cap to the gas bottle valve. — Never store the gas bottles below ground level (burrows and basements), in living accommodation and restrooms or in their vicinity and in thoroughfares. — Always store gas bottles in an upright position - even empty bottles.


1-11

Chapter 1

SAFETY

Gas Hose Routing

!

CAUTION

The hose rupture protector (4) must never be removed or installed in another position. Illustration 2

Table 3: Schematic illustration of the propane gas heating system

1-12

1

Gas bottle with canopy

11

Ignition electrode

2

Stop valve, gas bottle valve

12

Thermo element

3

Medium pressure controller

13

Gas burner, basic screed

4

Hose rupture protector

14

Sieve

5

Distributor with 2 stop valves

15

Solenoid valve

6

High pressure hose 6x5

16

Regulator and stop valve

7

Start button

17

Ignition warning lamp

8

Stop button

18

Operating warning lamp

9

Safety valve

19

Gas burner, Vario screed section

10

Burner

20

Gas burner, 1000 mm screed extension


SAFETY

Chapter 1

SAFETY PRECAUTIONS WHEN GAS ESCAPES

!

DANGER

Proceed as follows if you notice gas is escaping: •

Warn other people in the vicinity and instruct them to leave the danger zone.

•

Immediately close the valves on the gas bottles. NOTE: To close the bottle, turn the screw on the valve clockwise.

•

Ensure there is ample ventilation.

•

Extinguish all naked flames, cigarettes and other sources of ignition in the vicinity.

•

Do not switch on any electrical appliances because a flashover to the switching contact may occur and ignite the gas mixture.

•

If there is a danger that escaping gas cannot be brought under control or there is a danger of fire in the area of the heating system, immediately alarm the fire brigade and try to extinguish the fire yourself but do not subject yourself to danger. Immediately clear the danger zone of all persons.


1-13

Chapter 1

SAFETY

SAFETY PRECAUTIONS WHEN THE MACHINE TOUCHES LIVE ELECTRIC CABLES When paving, always keep the machine at an adequate safety distance to overhead electric cables. If work must be carried out in the vicinity of overhead electric cables, then ensure there is an adequate safety distance between the cables and parts and components on the paver.

!

DANGER

Proceed as follows if the machine touches live electric cables:

1-14

•

Remain seated on the operator's seat.

•

Do not touch any operating controls or any other parts of the machine.

•

Warn other persons not to touch the machine.

•

Have the current switched off at source.

•

Only leave the machine when you are absolutely sure that the damaged cable is dead.


CHAPTER 2 - INSTRUMENTS AND CONTROLS


2-1

Chapter 2

INSTRUMENTS AND CONTROLS


!

WARNING

In the interest of your own safety and the safety of others, you must thoroughly read and understand this chapter before operating the machine.

2-2



Chapter 2

MACHINE OVERVIEW Illustration 1:

Table 1: Pos.

Description

Function

1

Sun roof

All weather protection

2

Operator's platform with control panel

Operating the paver

3

First aid box compartment

Storing the first aid box and operating manual

4

Mat thickness scales

Indicates the approx. paving thickness

5

Hopper with conveyors

Loading the paver and conveying the material to the augers

6

Outrigger for direction indicator

Assist steering the machine during paving (e.g. along a taught reference wire)

7

Front Cross Beam

Pushing the dump truck

8

Road Scrapers

Clearing the surface in front of the undercarriage

9

Crawler Unit

Driving the paver

10

Fuel Tank

Refuelling the paver

11

Distributor augers

Distributing the material in front of the screed

12

Towing arms

Raising and lowering the paving screed

13

Paving screed

Compacting the material;Information on the paving screed is included in the screed's documentation

14

Gas bottle support

Mounting the gas bottles for the screed heating system

15

External control panel

Operating the screed

16

Emulsion spraying system

Cleaning the paver (Option)


2-3

Chapter 2


OPERATOR'S PLATFORM Illustration 2

Table 2: Pos.

2-4

Description

Function

1

Control panel cover

Protects the control panel from rain and dirt

2

Staple for padlock

Protection against vandalism

3

Guide tube

Cross-sliding the control column

4

Locking bolt hole

Secures the control panel against unintentional movement



Chapter 2

OPERATOR'S SEAT STANDARD SEAT

!

CAUTION

Sudden movements of the seat will cause injuries. Ensure that all adjusting levers lock into position after adjusting the seat. Only adjust the seat when the machine is at a standstill. Illustration 3:

Table 3: Pos.

Description

Function

1

Lever "operator's weight"

Setting the operator's weight

2

Lever "seat to & fro"

Longitudinal seat adjustment

3

Lever "backrest to & fro"

Adjusting the backrest inclination

Armrest

Armrest raise and lower

A-B


2-5

Chapter 2


DELUXE SEAT

!

CAUTION


Table 4: Pos.

Description

Function

1

Lever "seat to & fro"

Longitudinal seat adjustment

2

Lever "seat height / slope"

Adjusting the seat height and slope

3

Lever "backrest to & fro"

Adjusting the backrest inclination

4

Lever "operator's weight"

Setting the operator's weight

5

Button switch "seat heating" (Option)

Seat heating Front LH switch: Seat heating ON / OFF Rear RH switch: Backrest heating ON / OFF

2-6



Chapter 2

CONTROL PANEL Illustration 5:

Table 5: Pos.

Illustration

Description

Function

A1

Control lamp,engine oil temperature

Shows the temperature of the engine oil. The indicator needle must be in the green range during operation. If the needle moves into the red range, immediately stop the engine and eliminate the cause of overheating (e.g. engine overloaded, loss of coolant, dirty radiator).

A2

Fuel level indicator

Shows the level of fuel in the fuel tank. The exact level can only be shown when the machine is standing on level ground.

A3


No function has been allocated to this key

2-7

Chapter 2

Pos.

2-8


Illustration

Description

Function

A4

Operating hour meter

Shows the machine's number of operating hours.

A5a

Road lights


A5b

Flashing direction indicators


A5c

Battery charging lamp

Illuminates if the battery is not being charged due to a faulty generator or fault in the electrical system.

A5d

Control lamp engine oil pressure

Illuminates red if the oil pressure is too low (e.g. oil level too low). Immediately switch off the engine. An acoustic warning will sound 4 minutes after the red lamp illuminates.

A6a

Control lamp, engine coolant level

Illuminates red if the coolant level is too low. Let the engine run at idling speed for a few minutes and then switch it off. An acoustic warning will sound at the same time.Caution: Let the engine cool down before checking the coolant level. Also observe the "engine oil temperature" warning (A1).

A6b

Control lamp emergency STOP

Illuminates red when the emergency STOP button (A11) is pressed.

A6c

Control lamp hydraulic oil temperature

Illuminates red if the hydraulic oil temperature is too high. Immediately stop the paver. Let the engine run at a medium speed with the machine at a standstill to cool down the hydraulic oil.



Pos.

Illustration

A6d

Chapter 2

Description

Function

Control lamp spring loaded brake

Illuminates red when the brake is applied a) when the paver is switched OFF b) when the ignition is switched ON but the engine has not been started c) when the drive lever (A25) is in the zero position and the engine is running.

A7

Toggle switch, vibration

Select the operating mode for the vibration. Centre Position: Neutral, the vibrators are switched OFF. LH Position (MAN): The vibrators run permanently (for cleaning purposes or adjusting the hydraulics). RH Position (AUTO): The vibrators are switched ON when the drive lever (A25) is moved to the forward travel position. The vibrators are switched OFF when the drive lever is returned to the centre position. This mode is recommended for paving work.

A8a

Toggle switch, tampers

Select the operating mode for the tampers. Centre Position: Neutral, the tampers are switched OFF. LH Position (MAN): The tampers run permanently (for cleaning purposes or adjusting the hydraulics). RH Position (AUTO): The tampers are switched ON when the drive lever (A25) is moved to the forward travel position. The tampers are switched OFF when the drive lever is returned to the centre position. This mode is recommended for paving work.


2-9

Chapter 2

Pos. A8b


Illustration

Description Potentiometer, heavy duty tampers

Function Potentiometer for setting the tamper frequency. Potentiometer only with heavy duty tampers (variable displacement pump); refer to 227Page, Pos. 2.

A9

Speed potentiometer

Potentiometer for preselecting the travelling speed. The range of travelling speeds depends on the position of the speed stage toggle switch A13. Toggle switch A13 on Pos. L: 0 - 16 m/min (paving speed range) Toggle switch A13 on Pos. H: 0 - 60 m/min (transport speed range) A constantly controlled speed is only possible at a potentiometer setting of 0:7 m/min and higher.

A10

Control lamp, rapid lubrication

Activate the rapid lubrication at the end of daily paving work; the control lamp illuminates during the lubrication process.

A11

Emergency STOP button

Released: Normal operation

Release button for emergency STOP

Depressed: Emergency STOP released.

A12

Depressed: All drives and movements are stopped; the spring loaded brake is applied.

The emergency STOP button (A11) must be pulled upwards to release the emergency stop.

2-10



Pos.

Illustration

A13

Chapter 2

Description Toggle switch, speed stage selector switch

Function Switch for selecting the required speed stage. LH Position (L): Paving speed (Low, 0 - 16 m/min) RH Position (H): Transport speed (High, 0 - 60 m/min) The paver will automatically stop when changing speed stages onthe-run. Thereafter, turn the speed potentiometer to start the paver again.

A14

Toggle switch, turning on the spot

Used for turning the paver on the spot. This function can only be activated when the drive lever (A25) is in the zero position and the and the toggle switch (A13) for the speed stage selection has been moved to the LH position "L" (paving speed stage). LH Position (0): neutral Move the switch to the RH position (I): Turning on-the-spot function is activated. Rotate the steering potentiometer (A26) to select the direction for turning on-the-spot. The more you rotate the steering potentiometer (A26), the faster the paver will turn.

A15



2-11

Chapter 2

Pos. A16


Illustration

Description Toggle switch, RH tow point

Function Toggle switch for altering the paving thickness on the RH side. The tow point can only be manually adjusted when the toggle switch (A35) for the levelling system has been moved to the MAN mode. Centre Position: neutral Move the switch to the rear (upwards): Increase the mat thickness Move the switch to the front (downwards): Reduce the mat thickness

A17

Toggle switch, RH auger operating mode

Select the operating mode of the RH auger. LH Position (MAX): Maximum auger speed.In this position the auger will rotate even when the electronic control fails. RH Position (PROP): Proportional auger speed control according to material requirements (controlled by ultrasonic sensors)

A18

Toggle switch, RH Auger ON/OFF control

RH auger ON / OFF control. Centre Position: Auger is switched OFF. Move the switch to the left (MAX): The auger will rotate in the mode selected with the toggle switch A17. Move the switch to the right (AUTO): The auger will be proportionally controlled by the ultrasonic sensor.

A19

Toggle switch, RH conveyor operating mode

RH conveyor ON / OFF. Centre Position: Conveyor is switched OFF. LH Position (MAN): Conveyor is manually switched ON and OFF. RH Position (AUTO): The conveyor is controlled by the RH paddle type control switch.

2-12



Pos.

Illustration

A22

Chapter 2

Description Toggle switch, hopper wings

Function Hopper wings open and close. Centre Position: neutral Move the switch to the rear (upwards): Close the hopper wings. Move the switch to the front (downwards): Open the hopper wings. Mechanically secure the closed hopper wings with the locking bolts when transporting the paver.

A21

Toggle switch, Auger reverse mode

Determine the direction of rotation on both auger halves. Centre Position: neutral, the auger halves will convey the material outwards on both sides. LH Position: Both augers will convey the material to the LH side. RH Position: Both augers will convey the material to the RH side.

A22

Button switch, warning horn

Press the button to sound the warning horn. Sound the warning horn before moving the paver to warn other persons in the danger zone.

A23


Control lamp, rotary sensor

Flashes if the rotary sensor or its wiring fails on the RH or LH transmission gear.

2-13

Chapter 2

Pos. A24


Illustration

Description Ignition switch

Function Starting and stopping the engine From left to right: Position „P“: Parking position (P), the ignition key can be removed Position „0“: Engine cut-out (before stopping the engine, let it run for approx. 5 minutes without load at a higher speed to cool down). Position „1“: Switch on the ignition; the control lamps will illuminate Position „2“: Start the engine To start the engine, the drive lever (A25) must be in the neutral position.

A25

Drive lever

For driving the paver forward or backward up to the speed set on the speed potentiometer (A9). Release the drive lever by placing two fingers underneath and either side of the knob and lifting it gently. Centre Position: neutral, the pave is at a standstill and the spring brake is applied. Gently move the drive lever forwards as far as it will go: The paver travels forwards Gently move the drive lever backwards as far as it will go: The paver travels backwards All automatic functions (except the conveyors) can only be activated when the paver is travelling forwards.

2-14



Pos.

Illustration

A26

Chapter 2

Description Steering potentiometer

Function For steering the paver Centre Position: The paver travels straight ahead. Rotate to the left: The paver will travel in a left turn Rotate to the right: The paver will travel in a right turn

A27

Toggle switch, screed assist (Option)

Screed assist ON / OFF. The screed assist prevents the screed sinking downwards during paving work and improves the paver's traction. If required, a variable pressure between 10 and 50 bar can be applied to the screed transport cylinders. This pressure counteracts the weight of the screed and prevents it sinking into paving material with a low bearing capacity. This option does not effect the screed's floating behaviour; the screed will bear down on the material with a reduced load. LH Position (ON): Screed assist is switched ON RH Position(OFF): The screed assist is switched OFF


2-15

Chapter 2

Pos. A28


Illustration

Description Toggle switch, screed anti-climbing lock (Option)

Function Screed anti-climbing lock ON / OFF. If required, the screed transport cylinders can be hydraulically locked in position to prevent the screed from raising. The anti-climbing lock prevents the screed from climbing up and over paving material which has cooled down in front of the screed when the machine starts moving again after a stop in paving work. The screed anti-climbing lock will only function with the drive lever moved to the forward travel position and the screed switched to the floating mode. LH Position (ON): The screed anti-climbing lock will be switched on for approx. 10 seconds when the machine starts paving. RH Position(OFF): The screed anti-climbing lock is switched off.

A29

Toggle switch, screed floating mode

Screed floating mode ON / OFF. LH Position (0): The screed can be manually raised and lowered using the toggle switch (A31). RH Position (1): Screed floating mode Only switch on the floating mode after the screed has been lowered e.g. resting on squared timbers Ensure no persons are in the danger zone when raising or lowering the screed or during transport.

A30

2-16

Control lamp,screed floating mode

Illuminates when the screed has been switched to the floating mode (toggle switch A29 moved to position 1).



Pos.

Illustration

A31

Chapter 2

Description Toggle switch, Screed raise / lower

Function Screed raise and lower Move the switch to the rear:Screed raise Move the switch to the front (downwards): Screed lower

A32

Toggle switch, LH auger operating mode

Select the operating mode of the LH auger. LH Position (MAX): Maximum auger speed. RH Position (PROP): Proportional auger speed control according to material requirements.

A33

Toggle switch, LH Auger ON/OFF control

LH auger ON / OFF control. Centre Position: Auger is switched OFF. Move the switch to the left (MAX): The auger will rotate in the mode selected with the toggle switch A32. Move the switch to the right (AUTO): The auger will be proportionally controlled by the ultrasonic sensor.

A34

Toggle switch, LH conveyor operating mode

LH conveyor ON / OFF. Centre Position: Conveyor is switched OFF. LH Position (MAN): Conveyor is manually switched ON and OFF. RH Position (AUTO): The conveyor is controlled by the LH paddle type control switch.


2-17

Chapter 2

Pos. A35


Illustration

Description Toggle switch, Levelling system

Function Levelling system control. Centre Position: The levelling system is switched OFF. LH Position (MAN): The levelling system will function when the machine is paving and at a machine standstill. This permits the mat thickness to be corrected using the toggle switches (A16) for the RH tow point and (A37) for the LH tow point. We recommend to use this position only for setting up the levelling system at the start of paving work. RH Position (AUTO): The levelling system will control the mat thickness during paving work.This position is recommended for paving.

A36

A37


Toggle switch,LH tow point

Toggle switch for altering the paving thickness on the LH side. The tow point can only be manually adjusted when the toggle switch (A35) for the levelling system has been moved to the MAN mode. Move the switch to the rear (upwards): Increase the mat thickness Centre Position: neutral Move the switch to the front (downwards): Reduce the mat thickness

2-18



Pos.

Illustration

A38

Chapter 2

Description Lever, engine speed control

Function Throttle lever for engine speed. Move the lever upwards: Increase the engine speed Move the lever downwards: Reduce the engine speed


2-19

Chapter 2


EXTERNAL CONTROL PANELS The external control panels are mounted mirror inverted at the rear of the paver on the LH and RH sides. Illustration 6:

Table 6: Pos. B1

Illustration

Description Button switch, Increase mat thickness

Function Increase the angle of attack on the LH and RH side of the screed to increase the mat thickness. Ensure the tow points are not adjusted to opposite limit stops (one tow point to the upper and one tow point to the lower limit stop). This will cause undue torsion and twisting on the screed. The maximum permissible difference in height between the LH & RH mat thickness scales must not exceed 100 mm. Never operate the tow point adjustment when the screed is raised and secured in the transport locks otherwise damage will occur to the locking device.

2-20



Pos.

Illustration

Chapter 2

Description

Function

B2

Button switch, Reduce the mat thickness

Reduce the angle of attack on the LH and RH side of the screed to reduce the mat thickness. Refer to B1.

B3

Button switch,overmodulating the augers

For overmodulating the RH respectively the LH auger. Use the overmodulating function if you require a higher head of material in the auger channel for a short time (e.g. just before extending the Vario screed). The respective auger will rotate at maximum speed as long as you keep the button switch depressed. Condition: Pressure switch B7 is pulled upwards.

B4

Button switch,Vario screed extend

Extend the LH / RH Vario screed.The warning light B8 will flash when the Vario screed is extended.

B5

Button switch, Vario screed retract

Retract the LH / RH Vario screed. The warning light B8 will flash when the Vario screed is extended.

B6

Button switch, warning horn

Press the button to sound the warning horn.

B7

Pressure switch STOP material flow

The material flow (conveyors and augers) can be stopped separately on both sides if the head of material in the auger channel is too high. Released: Normal operation Depressed: LH respectively RH conveyor and auger will be stopped.

B8


Warning light Vario screed extend / retract

Flashes when the Vario screed is extended or retracted.

2-21

Chapter 2


STORAGE COMPARTMENTS Illustration 7:

Table 7: Pos.

2-22

Description

Location

1

Tool box tray

Underneath the deck plate on the operator's platform

2

Compartment for First aid box and operating manual

RH side on the operator's platform



Chapter 2

FUEL TANK Illustration 8:

Table 8: Pos. 1

Description Filler cap


Function Topping up with Diesel fuel; new pavers are supplied with the ignition key for the ignition switch (A24) fastened on the inside of the filler cap

2-23

Chapter 2


CENTRAL LUBRICATION SYSTEM (OPTION) The paver can be equipped with a central lubrication system located inside the RH side door; the system lubricates the paver at specified intervals.

!

CAUTION

Observe the following: •

The central lubrication system functions automatically.Nevertheless, check at regular intervals and ensure that lubricant emerges from the grease points.

•

The grease container must never run empty otherwise the pump must be deareated. Illustration 9

Table 9: Pos.

2-24

Description

Function

1

Central lubrication system

Lubricates the basic auger, conveyor drive shaft and conveyor idler shaft as well as the bearing arms

2

Lubricating point

Connection for the grease gun (4)

3

Pressure relief valve

Safety valve

4

Grease gun

Filling the grease container with lubricant



Chapter 2

MAT THICKNESS SCALES The mat thickness scales show the approximate thickness of the mat being paved. Instructions for mechanically altering the screed's angle of attack as well as for adjusting the mat thickness are included in the operating manual for your paving screed. Illustration 10:

Table 10: Pos. 1

Description Mat thickness scales


Function Indicates the approx. paving thickness

2-25

Chapter 2


EMULSION SPRAYING SYSTEM (OPTION)

!

CAUTION

Protect the environment by using a washdown point with a separator for cleaning the paver. If this is not possible on your job-site, then the cleaning solvent must be collected in a suitable container. Do not allow the cleaning solvent to seep into the ground. Fire hazard Do not use flammable cleaning solvents. Only start spraying the cleaning solvent after the burner chambers have cooled down (approx. 10 minutes after switching off the heating system). Illustration 11:

Table 11: Pos.

2-26

Description

Function

1

Stop valve

Hose connection with ball cock

2

Spraying lance

Spraying lance with nozzle

3

Level indicator

Shows the level of cleaning solvent in the tank

4

Filler cap

Top up with non-flammable cleaning solvent



Chapter 2

POTENTIOMETERS FOR VIBRATORS AND TAMPERS Illustration 12:

Table 12: Pos. 1

Description Potentiometer, vibrators

Function Setting the vibrators Rotate clockwise: reduce the vibrator speed Rotate anti-clockwise: increase the vibrator speed

2

Potentiometer, Tampers“ (This potentiometer is installed with the standard tampers without variable displacement pump). The potentiometer for the heavy duty tampers is located on the control panel -refer to 210Page, Pos. A8b)


Setting the tampers Rotate clockwise: reduce the tamper speed Rotate anti-clockwise: increase the tamper speed

2-27

Chapter 2


SWITCH OFF THE LEVELLING CYLINDERS IN CASE OF BREAKDOWNS

!

CAUTION

Always close both ball cocks on the levelling cylinders on both sides of the paver. If you only switch off the levelling cylinder on one side of the paver, the screed will be subject to excess torsion and will be damaged. Illustration 13:

2-28



Chapter 2 Table 13:

Pos. 1

Description Ball cock, levelling cylinder

Function Switch off the hydraulic circuit for the RH or LH levelling cylinder n case of a breakdown (Location:on the RH and LH levelling cylinders). Lever position vertical (as illustrated): Normal position, the ball cock is open, the hydraulic is switched on and the levelling cylinder is ready for operation Lever position horizontal: The ball cock is closed, the hydraulic circuit is blocked; the levelling cylinder is switched off. Levelling is not possible.


2-29

Chapter 2


SCREED HEATING SYSTEM (OPTION) Paving screeds can be heated by propane gas or Diesel fuel (only for Variomatic screeds) heating systems. The operating instructions for the propane gas or Diesel heating system installed on your particular screed are included in the screed's operating manual. There is a separate operating manual for the temperature controlled gas blower heating system (Thermo-Control). Strictly observe all locally prevailing directives and laws for operating the heating system on your paving screed. Secure the propane gas bottles against toppling over on the paver. Operating instructions for the propane gas or Diesel fuel heating system can be taken from the operating manual for your particular paving screed. The heating gas used should, if possible, be pure propane gas and at ambient temperatures above 10° C should have a maximum butane content of approx. 50%. Heating gases with a higher butane content should not be used because they do not develop sufficient vaporising pressure for the gas burners to operate in a stable manner. At ambient temperatures below + 10° C, the butane content may only amount to max. 30%. Some of the connections on the propane gas heating system have left-handed threads.These can be recognised by a groove in all six surfaces on the union nuts. The paver's scope of supply includes two canvas canopies for the gas bottles. Cover the gas bottles with the canopies as follows: 1. During all paver shut-downs when the ambient temperature is above 10° C. 2. When withdrawing gas for continuous paving work at ambient temperatures above 20° C and the gas bottles are exposed to sun rays. Using the canopies will avoid the gas bottles unduly warming up when exposed to sun rays leading to a high gas pressure in the bottles.

!

DANGER

At the end of paving work, close the valves on the gas bottles, the distributor and on the gas burners. Before transporting the paver, close the valves on the gas bottles, remove the gas hose with pressure reducer and fit the protective caps on the gas bottles.

2-30



Chapter 2

The following procedure must be strictly observed to ensure a burner run-down. Machines equipped with standard gas burners •

before switching off the paver's ignition, ensure that the toggle switch for the standard gas burners is moved to Pos. ON (I) to ensure a burner run-down.

Machines equipped with temperature controlled gas burners (Thermo-Control) •

before switching off the paver's ignition, ensure the operating mode switch is moved to the Pos. „AUTO“ or „MAN“ to ensure a burner run-down. Illustration 14:

Table 14: Pos.

Description

Function

1

Gas bottle connection

Gas hose with pressure reducer

2

Gas bottle tensioning belt

Securing the bottle against falling over


2-31

Chapter 2


ELECTRONIC LEVELLING SYSTEM (OPTION) When using an automatic levelling system you will obtain the best possible surface evenness. Using a grade control will require a reference surface (kerbstone, adjacent lane or tensioned levelling wire). We do not recommend using a levelling system for paving a wearing course if the previous binder course is smooth and level. Further information on the application of the optional levelling system is included in a separate instruction manual. Illustration 15

Table 15: Pos.

2-32

Description

Function

1

Support, Moba controller

For installing the optional Moba controller

2

Assembly plate Electronic levelling system

Assembly plate for the optional electronic levelling system



Chapter 2

ELECTRICS BATTERY MASTER SWITCH

!

CAUTION

Switch off the power supply with the battery master switch: •

before all maintenance and repair work on the paver to avoid short circuits.

•

at the end of paving work to ensure all users have been switched off. Illustration 16:

Table 16: Pos. 1

Description Battery Master Switch

Function Switch off the power supply at the end of work Vertical position: Power supply switched on (illustration refers) Horizontal position: Power supply is switched off (as an additional anti-theft measure, remove the plastic key from the master switch in this position at the end of work).


2-33

Chapter 2


WORKING LIGHTS Illustration 17:

Table 17: Pos.

2-34

Description

Function

1

Working lights

Illuminating the front and rear working area of the paver

2

Xenon floodlights (Option)

Illuminating the front and rear working area of the paver

3

Warning beacon (Option)

To improve safety in the working area;ON / OFF switch located on the roof strut

4

Additional Working Lights (Option)

For illuminating the auger channel



Chapter 2

SOCKETS / FUSES ON THE PAVER'S LH REAR WALL Remarks: Ensure the sockets are closed with the protective caps when not in use. This will avoid moisture and dirt damaging the sockets. Illustration 18:

Table 18: Pos.

Description

Function

1

24-V socket

Socket for the levelling system / LH slope controller

2

24-V socket

Socket for the working lights or additional working lights

3

24-V socket


4

Fuse box

Fuses F83 to F90 (refer to the allocation of fuses in the switch cabinet on the control column)

5

24-V socket

Socket for the gas burners on the Variomatic screed - basic width

6

24-V socket

Socket for the control cable; the socket must be connected during paving work otherwise the LH auger will not function


2-35

Chapter 2


SOCKETS ON THE PAVER'S RH REAR WALL Remarks: Ensure the sockets are closed with the protective caps when not in use. This will avoid moisture and dirt damaging the sockets. Illustration 19:

Table 19: Pos.

2-36

Function

FUNCTION

1

24-V socket

Socket for the levelling system / LH slope controller

2

24-V socket


3

24-V socket


4

24-V socket




Chapter 2

SOCKETS ON THE LH AND RH EXTERNAL CONTROL PANELS Remarks: Ensure the sockets are closed with the protective caps when not in use. This will avoid moisture and dirt damaging the sockets. Illustration 20:

Table 20: Pos.

Function

FUNCTION

1

24-V socket


2

24-V socket

Socket for the levelling system / LH and/or RH grade control

3

24-V socket

Socket for the ultrasonic sensor on the RH auger


2-37

Chapter 2


SWITCH CABINET ON THE OPERATOR'S PLATFORM Remarks: Please note that the switch cabinet may only be opened for short periods to perform any work. This will avoid moisture and dirt damaging the sockets. Illustration 21:

Table 21: Pos.

2-38

Description

Function

1

Fuses

Please refer to the overview of fuses (G2) on the inside of the switch cabinet door for the allocation of fuses

2

Plan of fuses and relays

Allocation of fuses and relays

3

Toggle switch, emergency control

The paver can be operated in emergency control if a fault occurs in the electronics Top position: Emergency operation Lower position: Normal operation



Chapter 2

SWITCH CABINET ON THE PAVER'S REAR WALL Remarks: Please note that the switch cabinet may only be opened for short periods to perform any work. This will avoid moisture and dirt damaging the sockets. Illustration 22:

Table 22: Pos.

Description

Function

1

Switch cabinet, screed heating

Setting the temperature on the screed heating

2

Switch cabinet

No operation required. Do not alter the settings! Refer to the circuit diagram for functions.


2-39

Chapter 2


SOCKETS ON THE PAVER'S REAR WALL Remarks: Ensure the sockets are closed with the protective caps when not in use. This will avoid moisture and dirt damaging the sockets. Illustration 23:

Table 23: Pos.

2-40

Description

Function

1

Connection, hydraulic crown control

Refer to the documentation for the screed

2

Socket

Not relevant for operation


CHAPTER 3 - OPERATION


3-1

Chapter 3

OPERATION

OPERATION

!

WARNING

Before operating the machine, thoroughly read and understand Chapter 1 “Safety”, Page 1-2 and Chapter 2 “INSTRUMENTS AND CONTROLS”, Page 2-2. Improper use and unexpected movements of the paver and moving parts can cause serious injuries and fatal accidents.

!

CAUTION

The engine output must be reduced if the Diesel engine is operated at temperatures of around 40° C and altitudes of around 1000 metres. The reduction of engine output may only be carried out by the engine manufacturer.

3-2


OPERATION

Chapter 3

IMPORTANT INSTRUCTIONS FOR OPERATION Strictly observe the following instructions when operating your paver: •

Use the handrails and steps when climbing up onto and leaving the machine and keep the working area free from dirt and ice.

•

Only put the machine into operation when all protective and safety devices are correctly installed and fully functional (e.g. working lights, removable safety systems, noise protection devices and exhaust system).

•

The operator must be well acquainted with his working surroundings. Observe any obstructions and other potential hazards in the working area and be aware of these sources of danger.

•

The paving crew must be acquainted with and use any hand signals required for the working process. Furthermore, a responsible person must determine the hand signals to be used.

•

The operator must not leave the operator's platform when the engine is running. Do not jump onto or down from the machine when it is moving.

•

Observe all warning and control lamps and indicators when stopping and starting the machine and be aware of any irregularities.

•

Switch on the working lights during poor visibility and twilight hours.

•

Before putting the machine into motion, ensure there are no persons or obstructions in the direction of travel or within the danger zone of the screed. Observe the paving width on both sides of the extended Variomatic screed.

•

Use extreme care and added caution when working on narrow job-sites or paving jobs with a high volume of traffic.

•

Use the drive lever and not the engine throttle lever to control the machine's speed.Do not accelerate a cold engine to a higher speed.

•

Ensure there is adequate headroom before driving the machine through bridges and tunnels, underneath overhead cables and across bridges.

•

Keep an adequate safety distance to trenches, ditches and slopes.

•

Sound the warning horn to warn persons in the vicinity before driving off and putting machine parts into motion. Give other persons sufficient time to leave the danger zone before moving the machine.

•

Before leaving the operator's platform, secure the machine against unintentional movement and unauthorised access. Remove the ignition key.

•

Park the machine on firm ground with sufficient bearing capacity.


3-3

Chapter 3

OPERATION

APPLICATION SPECIFIC SAFETY INSTRUCTIONS PAVING IN TUNNELS •

Ensure there is adequate ventilation

•

Ensure there is sufficient lighting in the tunnel.

•

Ensure suitable fire-fighting precautions have been taken.

PAVING IN THE VICINITY OF OVERHEAD ELECTRIC CABLES •

Ensure there is always an adequate safety distance between the paver and overhead electric cables. Otherwise a deadly conduction of electric current is possible. The safety distance depends upon the voltage in the overhead cables and the weather conditions.A conduction of current is possible at a distance of several metres at a high voltage and damp air.

•

Switch off the power in the overhead cables if it is not possible to keep an adequate safety distance.

•

If the machine makes contact with an electric power cable in spite of taking these precautions, refer to the procedures outlined in Chapter 1 “Safety precautions when the machine touches live electric cables”, Page 1-14.

PAVING IN CONTAMINATED AREAS •

Ensure the paving crew is not exposed to health risks when working in the vicinity or in contaminated areas such as waste disposal dumps etc.

•

Ensure the paving crew is wearing the required protective clothing.

•

Thoroughly clean the paver before leaving the contaminated area.

PAVING IN THE VICINITY OF RAILWAY LINES

3-4

•

Paving in the vicinity of railway lines with passing rail traffic is subject to increased danger which can lead to fatal accidents.

•

Only start work after obtaining permission from the railway authorities and after all necessary safety measures have been taken.

•

Pay continuous attention to the railway traffic and to the railway staff´s instructions, in order to immediately remove machine and persons out of the danger zone.

•

Ensure there is always an adequate safety distance between the paver and overhead electric cables. Otherwise a deadly conduction of electric current is possible. The safety distance depends upon the voltage in the overhead cables and the weather conditions. A conduction of current is possible at a distance of several metres at a high voltage and damp air.


OPERATION

Chapter 3

PAVING ON SLOPES •

Special safety precautions must be taken, such as securing the paver with a winch cable, when working on slopes where there is a danger of the machine toppling over or sliding away.

PAVING ON BRIDGES •

Ensure the weight bearing capacity of the bridge is sufficient to carry the weight of the paver and other machinery and equipment required for paving work.

•

Take the vibration effect of the screed into consideration.


3-5

Chapter 3

OPERATION

COMMISSIONING THE PAVER CHECK BEFORE COMMISSIONING THE PAVER

!

WARNING

Only put the machine into operation when you are absolutely sure that it is a perfect working condition. It is not permitted to use the machine if you know it is faulty. Rectify the faults or have them repaired by a service technician or your local distributor. Thoroughly check the machine before putting it into operation. 1. Ensure that all daily maintenance work is carried out.(refer to ”Daily procedure at the end of paving work”, page 3-61.) If necessary, top up fluids and complete maintenance work.Pay particular attention to: •

Cleanliness of all machine components

•

Fuel level

•

Coolant level

•

Engine oil level

2. Check the complete machine for loose, worn and missing parts. This specially applies to all safety devices.Renew any parts if necessary. 3. Check the following components for leakage: Gas heating system, fuel tank, fuel lines, hydraulic lines, hoses, filler necks, drain plugs, pressure valves, exhaust pipe, engine and components installed underneath the paver. 4. Ensure that the first aid box and operating manual are stored on the machine. 5. Remove all items not required for paving work. 6. Clean the paver.In particular, remove all dirt, water or ice from the operator's platform and in the vicinity of the external control panels which may pose a slip hazard. 7. Carry out the work described in the following sections and ensure the work has bee performed correctly.

3-6


OPERATION

Chapter 3

SWITCHING THE POWER SUPPLY ON AND OFF The power supply from batteries (2) is switched OFF with the battery master switch (1). The engine cannot be started if the power supply is switched OFF. Remarks: Switch off the power supply and remove the plastic key from the battery master switch: •

before starting maintenance and repair work to avoid short circuits and the paver being started during work.

•

at the end of paving work as an additional anti-theft and anti-vandalism measure. Illustration 4

1. Open the paver's RH side door. Ensure the retainer catch locks into position and prevents the door from closing. 2. Actuate the battery master switch 1: •

To switch ON the power supply: Turn the plastic key to the vertical position (as illustrated).

•

To switch OFF the power supply: Turn the plastic key to the horizontal position (90° anti-clockwise).

3. Release the retainer catch and close the door.


3-7

Chapter 3

OPERATION

SETTING UP THE OPERATOR'S PLATFORM A correctly set up operator's platform which provides the operator with an optimum view of the working area is a significant step towards avoiding accidents and damage to property.

!

CAUTION

Only start the paver after the operator's platform has been set up to ensure an optimum view of the working area and all platform components have been safely secured. During operation, all loose items must be removed from the paver as they can cause serious accidents.

3-8


OPERATION

Chapter 3

Raising and Lowering the Sun Roof

The height of the paver can be reduced for transport on a vehicle by lowering the sun roof.

!

CAUTION

The sun roof must be raised and safely secured against lowering with the bolts/nuts (2 and 3) for paving work. Otherwise it is not permitted to operate the paver on account of the restricted headroom. Before lowering the roof, the windscreen (if fitted) must be raised (refer to Chapter 3 “Windscreen (Option), Raising and Lowering”, Page 3-13). After the roof has been lowered, it must be secured against raising with the bolts/nuts 3. Illustration 5


3-9

Chapter 3

OPERATION

Raising the Sun Roof: 1. Remove both safety bolts (2) from the lower hinge joints on both front roof struts; these bolts have been placed there for safe keeping. 2. Remove the safety bolt (3) from the lower hinge joint on one of the rear roof struts (section A, position 4). Loosen the nut on the bolt 3 on the other rear roof strut. 3. Now stand on the steps to the operator's platform, pull the roof slightly downwards with one hand and use the other hand to remove the remaining bolt 3. Push the roof upwards until it is fully raised. 4. Fit the safety bolts 3 into the lower hinge joints on the rear roof struts. 5. Fit the lower safety bolts 2 to the lower hinge joints on both front roof struts. 6. Lower the front windscreen if installed on your on the paver (refer to Chapter 3 “Windscreen (Option), Raising and Lowering”, Page 3-13). Lowering the Sun Roof: 1. Move the control column to the centre of the platform and lock it in this position (refer to the safety decal). 2. Raise the front windscreen if installed on your on the paver (refer to Chapter 3 “Windscreen (Option), Raising and Lowering”, Page 3-13). 3. Remove the safety bolts 2 from the lower hinge joints on both front roof struts. 4. Remove the safety bolts 3 from the lower hinge joints on the rear roof struts. 5. Now stand on the steps to the operator's platform, grip the handrail with one hand to steady yourself and carefully pull the roof to the rear with the other hand. Caution! Danger of Injuries: A certain amount of force will be required to start the roof lowering; thereafter, the roof will lower easily, cushioned by the hydraulic springs. Take care not to bump your head when lowering the roof. 6. Secure the roof against raising by fitting the bolts 3 in the holes 4 and fastening the nuts (section A, position 4). 7. Replace the safety bolts with nuts 2 into both front roof struts for safe keeping.

3-10


OPERATION

Chapter 3

Exhaust Pipe, Fitting and Removing

The height of the paver must be reduced for transport on a vehicle. For this reason, remove the exhaust pipe.

!

CAUTION

Do not start the paver without the exhaust pipe, otherwise poisonous emission will be a health hazard to personnel in the vicinity. Illustration 6

1. Insert or remove the exhaust pipe from the pipe connection 1.


3-11

Chapter 3

OPERATION

Fitting the Side Curtains

The side curtains (1) protect the operator from rain and wind. Roll the side curtains up during good weather to obtain a better all round view. Illustration 7

Fitting the Side Curtains (1): Fit the side curtains (1) to the sun roof (2) and the roof struts (3) as illustrated. Removing the Side Curtains (1): Loosen and remove the side curtains (1) from the sun roof (2) and roof struts (3) as illustrated.

3-12


OPERATION

Chapter 3

Windscreen (Option), Raising and Lowering

The windscreen is raised to the rear and underneath the roof for transport.The windscreen is divided in the middle so that first one half and then the other half is raised. Raising the Windscreen: 1. Loosen the centre bolt connection. 2. Loosen the outer bolt connection on the outer edge of one half windscreen. 3. Raise the windscreen half up and underneath the roof and secure the outer bolt in the hole provided in the retainer plate. 4. Repeat step 3 with the other half of the windscreen. 5. Connect both raised halves of the windscreen in the middle with the connecting bolt. 6. Ensure both windscreen halves are safely secured in the raised position.

!

CAUTION

It is absolutely essential that the circlip is moved to the front as long as one or both windscreen halves are raised underneath the roof. Lowering the Windscreen: 1. Loosen the centre bolt connection. 2. Loosen the outer bolt connection on the outer edge of one half windscreen. 3. Lower one half of the windscreen downwards and secure the outer bolt in the hole provided in the retainer plate. 4. Repeat step 3 with the other half of the windscreen. 5. Connect both raised halves of the windscreen in the middle with the connecting bolt. 6. Ensure both windscreen halves are safely secured in the lowered position.


3-13

Chapter 3

OPERATION

Operator's Platform, Extending and Retracting

The operator's platform can be extended on both sides to improve the vision into the working area. The platform must be retracted for transport on a vehicle to minimize the paver's width. Illustration 8

Extending the Platform: 1. To extend the platform, release the locking devices (2) on the side of the paver required and lower the side plate (1). 2. To extend the roof, loosen the wing nut at Pos. 3 and unscrew the threaded bolt by a few turns. Remove any existing transport safety measures (e.g. cable straps). 3. Extend the roof outwards by max. 50 cm. 4. Tighten up the threaded bolt at Pos. 3 and secure with the wing nut. Retracting the Platform: 1. To retract the roof, loosen the wing nut at Pos. 3 and unscrew the threaded bolt by a few turns. 2. Retract the roof as far as it will go. 3. Tighten up the threaded bolt at Pos. 3 and secure with the wing nut. 4. To retract the platform, hinge the side plate 1 upwards and secure it with both locking devices 2.

3-14


OPERATION

Chapter 3

Seat Console, Extending and Retracting

After extending or retracting the platform, you can extend or retract the seat console. Illustration 9

1. Pull the lever 2 upwards until it is free of the hole 3. 2. Extend or retract the seat console 1 until it locks into the required position. 3. Ensure the lever bolt 2 has securely locked into the hole 3.


3-15

Chapter 3

OPERATION

Control Column, Cross Sliding

Position the control column according to the required sitting position. The control column may only be positioned in the locking holes provided on the platform's floor plate (LH or RH side on the extended or retracted platform). All other positions between these locking holes are not permitted. Illustration 10

1. Slightly tilt the control column to the rear (raise slightly) and cross slide it to the required position on the guide rail depending on which side you have the best view of the working area. 2. Lower the control column so that it locks into the hole 4 on the platform floor plate. Ensure the control column has safely locked into position. 3. Open the cover 1 on the control panel (if necessary, remove the padlock 2).

3-16


OPERATION

Chapter 3

Operator's Seat, Adjusting (Standard Seat)

!

CAUTION

Danger of injuries caused by sudden movements of the seat. Ensure that all adjusting levers lock into position after adjusting the seat. Only adjust the seat when the machine is at a standstill. Illustration 11:

1. To and Fro Adjustment: Pull the lever (2) upwards to unlock the seat. Hold the lever up and adjust the seat to the required position. Release the lever (2) to lock the seat in position. 2. Backrest Adjustment: Pull the front lever (3) upwards. Sit on the seat and use the weight of your body to adjust the seat's position. Thereafter, release the lever (3) to lock the seat in position. 3. Operator's Weight Adjustment: The weight setting can be varied with the lever (1). The number on the scale should correspond to the weight of the operator. The seat suspension is now set to the weight of the operator. First press the lever to the lowest position to return it to the upper position. 4. Armrest Adjustment: Tilt the armrests to position A or B.


3-17

Chapter 3

OPERATION

Operator's Seat, Adjusting (Deluxe Seat)

!

CAUTION


1. To and Fro Adjustment: Pull the bar lever (2) upwards to unlock the seat. Hold the bar lever up and push the seat to the required position. Release the bar lever to lock the seat in position. 2. Height and Slope Adjustment: Unlock the seat by pulling the lever (3) on the left-hand side upwards. Sit on the seat and use the weight of your body to adjust the seat's position. Thereafter, release the lever (3) to lock the seat in position. 3. Backrest Adjustment: Pull the lever (4) on the left-hand side upwards. Sit on the seat and use the weight of your body to adjust the seat's position. Thereafter, release the lever (4) to lock the seat in position. 4. Operator's Weight Adjustment: The seat's suspension can be adjust to the weight of the operator by turning the knob (1) at the front of the seat. The number which appears in the window must correspond to the weight of the operator. The seat suspension is now set to the weight of the operator. 5. Armrest Adjustment: By turning the knob (5), you can adjust the height and angle of the armrests. 6. Seat Heating (Option): Switch the seat heating on and off with the switch (6). The engine must be running to operate the seat heating.

3-18


OPERATION

Chapter 3

STARTING THE ENGINE

!

CAUTION

Only start the engine if: •

the paver is in a perfect functional condition and equipped with all safety devices supplied with the machine.

•

the operating personnel are fully qualified and fully acquainted with all controls and instruments.

•

no repair or maintenance work is being carried out on the paver.

•

the platform is correctly equipped and set up, no access doors are open and no loose objects are on the paver.

•

the surroundings are well ventilated.


3-19

Chapter 3

OPERATION

Starting the Engine with the Starter Batteries

Illustration 13

1. Return all operating elements on the control panel to the zero position: Toggle switches to „0“ or „OFF“ position, drive lever (A25) to the centre neutral position, speed potentiometer (A9) and steering potentiometer (A26) to „0“. 2. Check that the emergency STOP button (A11) has been pulled upwards and the drive lever (A25) is in the centre neutral position. If the control lamp "emergency STOP" (A6b) illuminates, press the button switch (A12) to release the emergency STOP. 3. Move the engine throttle lever (A38) to 1/4 speed. 4. Start the engine: •

Insert the ignition key in the ignition switch (A24). (The paver is supplied with the ignition key fastened to the inside of the filler cap).

•

Turn the ignition key to position 1.

•

Turn the ignition key to position 2 "Engine Start". Release the key as soon as the engine starts.

Remarks: Do not actuate the starter for more than 20 seconds as the starter motor will overheat. If the engine cannot be started at the first time, wait for 2 to 3 minutes before attempting another start. 5. With the exception of the spring loaded brake (A6d), check and ensure that all other control lamps are extinguished. If not, immediately switch off the engine and rectify the fault. 6. Move the engine throttle lever (A38) to the lowest speed. 7. Let the engine run warm for a short time to bring the hydraulics and the engine up to operating temperature. However, ensure the engine does not run for more than 10 minutes at idling speed.

3-20


OPERATION

Chapter 3

Jump Starting the Engine

!

WARNING

Strictly observe the following instructions when jump starting the engine. Ignoring these instructions will lead to accidents, serious injuries and possibly death. •

Exercise extreme caution when jump starting the engine.

•

Wear protective goggles when working on or in the vicinity of batteries.

•

Lead acid batteries develop explosive gases when being charged. Keep naked flames and sparks away from batteries.

•

Do not touch either machine during the jump starting process.

•

Do not start the machine by connecting the jumper cable to the starter motor or starter solenoid switch because this will bridge over the safety device installed on the machine. There is also a danger of the machine being put into motion and running over the people carrying out the jump start.

•

Never attempt to jump start a machine with frozen batteries as this will cause the batteries to explode.

•

Before jump starting the machine, disconnect all electronic equipment (e.g. levelling system) from the power supply as this will be damaged by peaks in the voltage.


3-21

Chapter 3

OPERATION Illustration 14:

1. Open the paver's RH side door. 2. Check and ensure that the battery master switch(1) is turned to the ON position (horizontal). 3. Connect one end of the jumper cable to the plus (+) terminal on the external battery and the other end to the plus (+) terminal on the machine's flat battery (2). 4. Then connect one end of the jumper cable to the minus (-) terminal on the external battery and the other end to the minus (-) terminal on the machine's flat battery (2). 5. Now start the engine (Chapter 3 “Starting the Engine with the Starter Batteries”, Page 3-20) 6. Remove the jumper cable which connects the minus (-) terminals. 7. Then remove the jumper cable which connects the plus (+) terminals. 8. Close the side door.

3-22


OPERATION

Chapter 3

STOPPING THE ENGINE

!

CAUTION

Immediately stop the engine if: •

a dangerous situation occurs.

•

the operator leaves the paver.

•

any work must be carried out on the paver. Press the emergency STOP button (A11) in dangerous situations to stop the engine and all moving components. Illustration 15

1. Return all operating elements on the control panel to the zero position: Toggle switches to „0“ or „OFF“ position, drive lever (A25) to the centre neutral position, speed potentiometer (A9) and steering potentiometer (A26) to „0“. 2. Move the engine throttle lever (A38) to the lowest speed. Depending on the previous load, let the engine run for a time to cool down (but not longer than 10 minutes). 3. Turn the key in the ignition switch (A24) to the "P" position (Park). 4. Remove the key before leaving the paver.


3-23

Chapter 3

OPERATION

STARTING AND STOPPING THE PAVER

!

CAUTION

Observe the following before driving the paver:

3-24

•

It is not permitted to operate the paver on public roads.

•

Secure or remove any loose objects on the paver.

•

Check the fuel level on the control panel. Refuel if necessary (Chapter 3 “Refuelling the Paver”, Page 3-30)

•

Switch on the working lights during poor visibility and twilight hours.

•

Inspect and become acquainted with the immediate working area. Pay particular attention to all possible hazards such as potholes in the road surface, slopes and inclinations, underground culverts, manhole covers, drainage ditches, kerbstones and/or roads.

•

The maximum permissible inclination is a slope of 25%.

•

Before putting the machine into motion, ensure there are no persons or obstructions in the direction of travel or within the danger zone of the screed. Observe the paving width on both sides of the extended Variomatic screed.

•

Sound the warning horn before driving off or changing directions.

•

When steering track mounted machines, the front and rear will swing out when cornering. Therefore, keep a safe distance to persons, buildings and other obstacles.


OPERATION

Chapter 3

DRIVING THE PAVER ON ROADS AND JOB-SITES

!

CAUTION

When driving the paver on roads and job-sites there is a danger of fatal accidents and serious damage. Closely observe the following when driving the paver: •

It is not permitted to operate the paver on public roads.

•

Observe the extended width of the screed when transporting the paver on job-sites.

•

If necessary, ballast must be placed in the hopper to act as a counter weight to the screed. Ballasting is not necessary if the paver is driven at a very slow speed.

•

When driving the paver on the job-site, disconnect the gas bottles and fit the protective caps (Chapter 2 “Screed Heating System (Option)”, Page 2-30).

•

Switch on the warning beacon and mount warning plates if required by your locally prevailing traffic code. Illustration 16

1. Close and lock the hopper wings (Chapter 3 “Hopper Wings, Open and Close”, Page 3-36). 2. Dismantle any screed extensions (refer to the documentation for the screed). Reduce the Vario extensions to the minimum width on Variomatic screeds (Chapter 3 “Variomatic Screed, Extend and Retract”, Page 3-39). 3. Dismantle any other components which may be an obstacle or accident prone during transport. For example, the auger extensions or direction indicator. 4. Raise and secure the screed in the transport locking device (refer to Chapter 3 “Screed Transport Lock”, Page 3-36). 5. raise the augers to the uppermost position (Chapter 3 “Auger Height Adjustment”, Page 3-42).


3-25

Chapter 3

OPERATION

6. Move the engine throttle lever (A38) to the maximum speed. 7. Move the toggle switch (A13) to the transport speed stage (H). 8. Turn the steering potentiometer (A26) to the centre zero position. 9. Turn the speed potentiometer (A9) to the required travelling speed. Govern the speed with the engine throttle lever. 10. Ensure no persons are in the direction of travel and sound the warning horn to warn person in the danger zone. 11. As soon as you move the drive lever (A25), the spring loaded brake will be released and the paver will start moving. •

Push the drive lever (A25) forwards and the paver will travel forward.

•

Pull the drive lever backwards and the paver will travel in reverse.

•

Return the drive lever to the centre neutral position to stop the paver.

12. Use the steering potentiometer (A26) to steer the paver.

3-26


OPERATION

Chapter 3

TURNING ON-THE-SPOT) Illustration 17

The function of turning on the spot will not operate if the electronic control for the travel drive is faulty. 1. Stop the paver by returning the drive lever (A25) to the neutral zero position. 2. Move the toggle switch (A13) to the low paving speed stage (L). 3. Turn the steering potentiometer (A26) to the centre zero position. 4. Move the toggle switch "Turning on the spot" (A14) to position "1" and keep it in this position. 5. Ensure nobody is in the paver's slewing range and sound the warning horn to warn persons in the danger zone. 6. The paver will turn on the spot as soon as you turn the steering potentiometer (A26): •

Turn the paver to the right: Rotate the steering potentiometer (A26) to the right

•

Turn the paver to the left: Rotate the steering potentiometer (A26) to the left

•

The more you rotate the potentiometer, the faster the paver will turn.

7. As soon as the paver has reached the required direction, return the steering potentiometer (A26) to the centre zero position and release the toggle switch "Turning on the spot" (A14).


3-27

Chapter 3

OPERATION

OPERATING THE PAVER IN AUXILIARY CONTROL (EMERGENCY CONTROL) The electronic control for the travel drive will automatically switch to auxiliary control if a failure occurs on one of the rotary sensors. A faulty sensor will be indicated by the control lamp for the rotary sensor flashing. The system must be switched to auxiliary control if the electronic control fails. To do this, open the rear door on the control column and move the switch (1) upwards to the auxiliary control position. Illustration 18

Operating the paver in auxiliary control will be the same as in normal control, i.e. use the drive lever (A25, 27Page), the speed potentiometer (A9, 27Page) and the steering potentiometer (A26, 27Page) refer to ”Driving the Paver on Roads and Job-sites”, page 3-25. Remarks: When operating the paver in the auxiliary control mode, acceleration and braking will react a lot slower. Therefore, we recommend to start and stop the paver by rotating the speed potentiometer (A9, 27Page). Starting the paver

1. Rotate the speed potentiometer (A9, 27Page) to the centre zero position. 2. Move the drive lever (A25, 27Page) to the required direction of travel. 3. Rotate the speed potentiometer (A9, 27Page) to accelerate the paver to the required speed. Stopping the paver

Remarks: Only stop the paver by pressing the emergency STOP button (A11, 27Page) in cases of danger. 1. Rotate the speed potentiometer (A9, 27Page) to the centre zero position. 2. Return the drive lever (A25, 27Page) to the centre zero position.

3-28


OPERATION

Chapter 3

PREPARING THE PAVER FOR OPERATION

!

CAUTION

Cordon off the working area. When preparing the paver for operation, only those persons involved with setting-up work may enter the working area. During operation, the paver's engine may only be started when it is absolutely necessary for paving work. A running engine is an increased risk of accidents. Therefore, work with exceptional caution.

NOTICE Drive the paver to its working position parallel to the lane to be paved. Refuel beforehand if necessary.


3-29

Chapter 3

OPERATION

REFUELLING THE PAVER The fuel tank is located on the RH side of the paver. The fuel level is shown on the fuel level indicator (A2, 27Page) on the control panel. The exact level can only be shown when the machine is standing on level ground.

!

CAUTION

Fire risk: Do not smoke and avoid sparks and naked flames when refuelling. •

Switch off the engine and ensure a good ventilation when refuelling.

•

Wear protective clothing to protect your eyes, hands and respiratory passages.

•

Do not spill any fuel when refuelling the machine. Immediately remove any fuel spilled.

NOTICE Never let the fuel tank run dry, otherwise the entire fuel system must be dearated. Refuel the paver at the end of a working shift to prevent condensation forming in the tank.

3-30


OPERATION

Chapter 3 Illustration 19

1. Switch off the paver's engine. 2. Unlock and remove the filler cap (1) by turning it slowly anti-clockwise. 3. Remove the strainer (2) from the filler neck and clean it with Diesel fuel if required. Correctly dispose of any used Diesel fuel. Do not let it escape into the environment. 4. Carefully refuel with a quality of Diesel fuel specified in the list of "Fuel, Oils, & Lubricants". 5. Close and lock the filler cap (1) by turning it clockwise.


3-31

Chapter 3

OPERATION

LUBRICATING THE PAVER The paver is equipped with a central lubrication system located inside the RH side door. During paver operation, the following assemblies will be automatically lubricated at specified intervals (i.e. for 16 minutes every two hours): •

Basic Augers

•

Conveyors including the conveyor drive shaft and the conveyor idler shaft.

•

Auger bearing arms.

Ensure the grease container is adequately filled with grease when putting the paver into operation. Before and after paving work, activate the rapid lubrication function by pressing the illuminating button switch H10 for the "Rapid Lubrication".

!

CAUTION

Observe the following:

3-32

•

Only operate the central lubrication with the pressure relief valve installed in the system and ensure the valve is functional. If grease appears out of the pressure relief valve, at least one lubrication circuit has a blockage and the respective lubrication point will no longer be supplied with grease. Immediately remove the blockage.

•

The central lubrication system functions automatically. Nevertheless, check at regular intervals and ensure that lubricant emerges from the grease points.

•

The grease container must never run empty otherwise the pump must be deareated.


OPERATION


1. Check the MIN and MAX level marks on the grease container to ensure there is sufficient lubricant in the system. If the level is too low: •

Switch off the paver's engine.

•

Fill the grease gun (4) with grease according to the list of "Fuel, Oils & Lubricants".

•

Remove the threaded cap (2).

•

Insert the grease gun (4) on the connection and pump grease into the container until the MAX level mark has been reached.

•

Replace the threaded cap (2) on the connection.

2. Start the engine and press the illuminating button switch for a rapid lubrication (A10, 27Page) on the control panel. The control lamp illuminates during the lubrication process.

NOTICE Carry out point 2 before and after paving work.


3-33

Chapter 3

OPERATION

FRONT CROSS BEAM The front cross beam (3) is attached to the front of the basic frame by a bolt (4). Buffer rollers (5) are fitted to the front cross beam for pushing the truck when it charges the hopper. The oscillating suspension of the front cross beam is designed to take up steering movements between the paver and the dump truck during the charging process. Illustration 21

1. Whenever necessary, clean off any bitumen and dirt which has accumulated on the truck buffer rollers (5).

3-34

•

Scrape or brush off solid material

•

Remove bituminous materials with the emulsion spraying system

•

Use water to remove any non-bituminous material


OPERATION

Chapter 3

ROAD SCRAPERS, RAISING AND LOWERING Road scrapers (2) are mounted in front of the LH and RH crawler tracks. The road scrapers are lowered for paving work to clear away any obstacles such as paving material spilled out of the hopper from the path of the crawler tracks.

!

WARNING

The road scrapers must be raised for transporting and loading the paver. Otherwise they will be damaged. Illustration 22he

Lowering the Road Scrapers

1. Hold the road scraper (2) in the raised position. 2. Turn the spring loaded locking bolt (3) through approx. 180 degrees. 3. Slowly lower the scraper (2). Raising the Road Scrapers

1. Raise the lowered road scraper (2) by hand. 2. As soon as the hole coincides with the spring loaded locking bolt (3), turn it through approx. 180 degrees. Adjusting the Road Scrapers

The road scrapers (2) should touch the ground when the screed is in the raised position. By raising the screed, the paver's centre of gravity will be transferred to the rear of the machine. 1. Adjust the height of the road scraper (2) with the adjusting screw (4) as previously described.


3-35

Chapter 3

OPERATION

HOPPER WINGS, OPEN AND CLOSE

!

WARNING

Close and lock both hopper wings before transporting the paver. Otherwise there will be an increased risk of danger because the hopper wings protrude beyond the basic width of the paver. Illustration 23

The hopper (1) is fitted with two wings. The hopper serves as a bunker for the paving material during paving work. The hopper wings can be closed to completely empty the hopper during paving work. The hopper wings must always be opened for the dump truck to charge the hopper. Hopper Wings, Open and Close

1. Use the levers (2) to release both hopper wings. Both locking hooks (3) must be completely free. 2. Ensure there are no persons or obstacles in the danger zone and sound the warning horn to warn other persons of a potential danger. 3. Use the toggle switch A22 on the control panel to open and close the hopper wings. 4. Use the levers (2) to lock the hopper wings in the closed position. The LH and RH locking hooks (3) must safely lock into position.

SCREED TRANSPORT LOCK The screed transport lock is a manually operated mechanical locking device. The towing arms (2) rest in the hooks (1) and secures the screed against lowering during transport. This will relieve the load from the screed transport cylinders.

3-36


OPERATION

Chapter 3

!

WARNING

The screed must be raised and secured in the transport lock before loading and transporting the paver. Otherwise it may collide with the ground and be damaged. Never alter the position of the tow points if the screed is raised and secured in the transport lock,i.e. do not actuate the toggle switches A16 and A37 (27Page). Otherwise the transport locking device will be damaged. Illustration 24


3-37

Chapter 3

OPERATION

Raising and Securing the Screed in the Transport Lock 1. Move the toggle switch A29 for the "screed floating mode" to the LH "O" position. (manual control). 2. Ensure there are no persons or obstacles in the danger zone and sound the warning horn to warn other persons of a potential danger. 3. Move the toggle switch A31 „screed raise / lower“ to the raise position until the towing arms have reached their highest position. 4. Move the levers (3) to the lower position in the slotted gate on both sides of the paver. The spring loaded locking hooks (1) will grip underneath the towing arms (2). 5. Move the toggle switch A31 „screed raise / lower“ to the lowering position until the screed transport cylinders are relieved of load. Releasing and Lowering the Screed from the Transport Lock 1. Move the toggle switch A29 for the "screed floating mode" to the LH "O" position. (manual control). 2. Ensure there are no persons or obstacles in the danger zone and sound the warning horn to warn other persons of a potential danger. 3. Move the toggle switch A31 „screed raise / lower“ to the raise position until the towing arms have reached their highest position. 4. Move the levers (3) to the upper position in the slotted gate on both sides of the paver. The spring loaded locking hooks (1) will retract and release the screed. 5. Move the toggle switch A31 „screed raise / lower“ to the lowering position until the screed rests on the ground.

3-38


OPERATION

Chapter 3

VARIOMATIC SCREED, EXTEND AND RETRACT

!

WARNING

When extending or retracting the Variomatic screed, the operator must keep the respective side well within his vision so that he can immediately stop the screed if there is a danger to persons in the vicinity. The screed must be retracted to the basic width before transporting the paver. Otherwise there will be an increased risk of danger because the extended screed will be wider than the basic width. Raise and secure the screed in the transport lock for transport and when working on the screed. Illustration 25

1. Ensure there are no persons or obstacles in the danger zone and sound the warning horn to warn other persons of a potential danger. 2. Press the button switch B4 or B5 and keep it pressed to extend or retract the screed. Button switches B4 and B5 are located on both LH and RH external control panels.


3-39

Chapter 3

OPERATION

SCREED TENSIONING DEVICE, ASSEMBLING AND DISMANTLING The screed tensioning device will improve the paving behaviour especially on Variomatic screeds at large widths. It has a permanent positive influence on the screed's floating behaviour and ensures a positive angle of attack. A support plate (A) prevents the tensioning cylinders on the screed tensioning device from dropping downwards. We recommend the application of the screed tensioning device on Variomatic screeds at paving widths beyond 7.0 m and on manually extendable screeds at paving widths beyond 10.0 m. The screed tensioning device must always be used on Variomatic screeds at paving widths of 9.0 metres.

!

WARNING

Before operating the screed tensioning device, ensure there are no persons in the danger zone or even working on the device itself. Ensure the wire rope does not wind around the auger extensions when retracting the Variomatic screed. Check the clamps (8) on the wire rope for tightness before using the screed tensioning device.

3-40


OPERATION

Chapter 3 Illustration 26 (example shown on a wheeled paver)

1. Extend the screed to its maximum paving width (refer to ”Variomatic Screed, Extend and Retract”, page 3-39). 2. Fit the tensioning cylinder (3) into the swivel bracket (4). 3. Connect the hydraulic hoses (5) to the tensioning cylinder. 4. To extend the ram on the hydraulic cylinder, swap the hoses (5) to opposite connections. Thereafter, return the hoses to the correct connections. 5. Use the shackle (6) to connect the wire rope (1) to the eye on the tensioning cylinder (3). 6. Bolt the connecting plate (2) to the end plate on the Variomatic screed. 7. Use the shackle (7) to fasten the wire rope (1) to the connecting plate. The wire rope must be slack when the Variomatic screed and the tensioning cylinder are both fully extended. 8. Move the toggle switch for the screed tensioning device to the ON position. Both tensioning cylinders will tighten the wire rope and the screed is now tensioned. The screed can be extended and retracted and the tension on the wire rope remains constant. Remarks: To dismantle the screed tensioning device, use the quick action couplings (10) to swap the hydraulic hoses (5) to opposite connections. The ram on the hydraulic cylinder can now be retracted. Thereafter, return the hoses to the correct connections. Thereafter, proceed in the reverse sequence described above.


3-41

Chapter 3

OPERATION

SCREED SPACER BLOCKS (OPTION) Screed spacer blocks are used for paving thicker mats to increase the width of the auger channel.

WARNING

!

There is an increased risk of accidents when fitting the screed spacer blocks because the paver must be moved during this work. Therefore, work with exceptional caution. Illustration 27

Fitting the Screed Spacer Blocks 1. Completely lower the screed to the ground. 2. Remove the 4 standard bolts (3) from the flanges (2). 3. Drive the paver forward by approx. 60 mm. 4. Insert the 2 spacer blocks between the flanges (2). 5. Insert and tighten the 4 longer bolts (3). Removing the Screed Spacer Blocks 1. Completely lower the screed to the ground. 2. Remove the 4 long screws (3) from the flanges (2). 3. Drive the paver forward by approx. 10 mm. 4. Remove the spacer blocks from between the flanges (2). 5. Drive the paver backwards by approx. 70 mm. 6. Insert and tighten the 4 standard screws (3).

AUGER HEIGHT ADJUSTMENT The augers () are mounted on the paver's rear wall. The augers laterally distribute the paving

3-42


OPERATION

Chapter 3

material in the auger channel. The augers are controlled by rubberised level switches, optionally by ultrasonic sensors, mounted on the auger outer bearings or LH and RH screed end plates. The installation of the optional ultrasonic sensors is described in the operating manual for the screed. When paving thinner mats, the head of material in the auger channel can be reduced with the augers in a lower position. This will reduce the shearing resistance on the screed and improve traction.

!

WARNING

Wear gloves when working on the augers. The surfaces of the mix conveyor system have sharp edges and may still be hot shortly after paving work. Ensure the augers do not collide with the ground when driving the paver or loading it on a transport vehicle; this would lead to damage on the augers. Raise the augers if necessary.


3-43

Chapter 3

OPERATION

Adjusting the Height of the Basic Augers

Remarks: The following instructions apply to augers with mechanical height adjustment (illustration refers) and augers with hydraulic height adjustment. Both versions are available with centre auger drive (illustration refers) and outer auger drives. Illustration 28:

1. If installed, disconnect the auger extensions with outer bearings from the basic auger or use suitable lifting tackle to adjust their height (refer to „Adjusting the Height of Auger Extensions with Outer Bearings“). Remarks: The augers can be adjusted to any height within the adjusting range if only the basic augers or the basic augers with auger extensions but without auger outer bearings are used. In this case, the locating bolt (1) will not be required and should be screwed into the adjacent hole for safe keeping. If the paver is fitted with auger outer bearings, the augers may only be adjusted to the positions of -30 mm, 0 mm or +30 mm because the outer bearing will only permit these adjustments. In this case, the locating bolt (1) must be used. 2. If fitted, unscrew and remove the locating bolt (1) from the paver's rear wall. 3. To set the mechanical height adjustment, turn the barrel nut on the turnbuckle (1) to raise or lower the augers by up to 30 mm from the zero position (the holes for the locating bolt are positioned at -30 mm, 0 mm ,+30 mm). To set the hydraulic height adjustment, raise or lower the augers by pressing the switch (3) located on the LH seat console in the required direction. 4. If necessary (Remarks refer), secure the setting with the locating bolt (1).

3-44


OPERATION

Chapter 3

Adjusting the Height of the Augers with Outer Bearings

Illustration 29: Auger extensions with outer bearings

1. Slightly raise the outer end of the auger extension (5) with a suitable lifting device. Do not exert any pressure on the bearing holder. 2. Loosen and remove the screws (4) from the bearing arm (3). 3. Raise or lower the auger extension with the lifting device until it has reached the same level as the basic augers. 4. Replace the bearing arm (3) using the screws (4) and tighten the screws. 5. Remove the lifting device. 6. Repeat this procedure on the other auger side.


3-45

Chapter 3

OPERATION

FITTING AUGER EXTENSIONS

!

WARNING

Switch off the Diesel engine before fitting any auger extensions. Worn auger flights have sharp edges. Wear working gloves to protect your hands. Auger flights must be fitted to clean surfaces without free play. Protect the ends of the auger shafts against wear by fitting the protective end caps. Fit the protective guards above the auger extensions. Protective guards are supplied for the auger channel on manual screeds and for the height adjustable channel plates on Variomatic screeds. Auger extensions must be dismantled for transport. Otherwise there will be an increased risk of danger because the auger extensions protrude beyond the basic width of the paver.

3-46


OPERATION


The configuration of the auger extensions and protective guards for each particular paving width is contained in the screed assembly plan. 1. Remove the protective end cap and screw from the basic auger shaft. 2. Connect the auger channel plate (4) to the paver's frame with the screws (2). 3. Connect the horizontal brace (3) between the channel plate (4) and the bracket on the paver. Use the front connecting bolt (1) with safety clip on the paver and the connecting bolt (5) on the channel plate to secure the horizontal brace. 4. use the turnbuckle (1) on the horizontal brace (3) to align the auger channel plate with the paver's rear wall. 5. Use the vertical brace (7) to connect the auger channel plate (4) to the paver's upper connecting lug. Secure the brace with the connecting bolts and safety clips (6 & 8). 6. Adjust the turnbuckle on the vertical brace (7) so that the auger channel plate is at an angle of 90 degrees to the paver's side wall. 7. Push the auger extensions (20) onto the basic auger. Ensure the pitch on the basic auger and auger extension is the same. 8. Connect both coupling pieces (11) with the screw (10) and fit a 140° auger flight (9) if required. 9. Fit the bearing arm (18) with the screws (19) to the support plate (17). The auger extension must be adjusted to the same height as the basic auger.


3-47

Chapter 3

OPERATION

10. Fit the end cap (15) with a screw to the end of the auger extension shaft. A 140° auger flight (16) can be fitted with a M20 x 140 screw to improve the distribution of the paving material. 11. Fit the hinged end plate (14) to the bracket (13) using the screws (12) as illustrated. 12. Finally ensure that all protective guards (21) have been fitted and that they are not damaged. 13. Stretch a piece of string across the entire width of the augers and check the horizontal and vertical alignment of the auger extensions (20) with the basic augers. Remarks: With the exception of the auger flight pitch, the assembly of the left- and right-hand augers is the same. The assembly of the adjustable channel plate is the same for auger extensions with or without auger outer bearings. The length of the adjustable channel plate and the auger extensions vary according to the particular paving width. Remarks: The adjustable channel plates achieve a more uniform distribution of material in front of the screed. The pitch of the 140° auger flight must be the same as the pitch on the basic auger. If mix segregation occurs in the area of the auger outer bearing, it can be rectified by swapping the flights. Remarks: Fit a right-hand auger flight to the left-hand side and vice versa. The same applies to the 140° auger flight at the end of the auger shaft.

3-48


OPERATION

Chapter 3

AUGER CONTROL, ADJUSTING

!

WARNING

Wear gloves when working on the augers. The surfaces of the mix conveyor system have sharp edges and may still be hot shortly after paving work. Illustration 31

The auger control consists of two rubberized level switches. The level switches are mounted at different positions depending on the paving width. Small paving widths: Mount the rubberized level switches at position (1) as illustrated. Large paving widths: Mount the rubberized level switches at position (2) as illustrated. Remarks: The flat side of the rubberized level switches must always face towards the paving material. Immediately renew faulty components with genuine parts.


3-49

Chapter 3

OPERATION

ADJUSTING THE CONVEYOR CONTROL (PADDLE TYPE CONTROL SWITCHES) The paddle type switches (1) are located on either side of the auger drive case on the rear of the paver. They control the flow of material during paving work. The conveyor control is correctly adjusted when the augers are submerged by approx. 2/3 in the paving material.

!

WARNING

Switch off the engine and remove the ignition key before adjusting the paddle type conveyor control switches. Wear gloves to adjust the paddle type control switches. Illustration 32

Too much material in the auger channel 1. Push the paddle type control switches (1) towards the paver's rear wall. Not enough material in the auger channel 1. Pull the paddle type control switches (1) away from the paver's rear wall.

3-50


OPERATION

Chapter 3

DIRECTION INDICATOR, SETTING UP The direction indicator is installed in position A at the front of the basic frame (1) below the cross beam (3). The direction indicator will assist you in steering the paver during paving work. You can accurately steer the paver by guiding the indicator chain along a reference surface such as a tensioned wire.

!

WARNING

The direction indicator protrudes beyond the basic width of the paver during paving work. Observe the extended width when driving the paver. Illustration 33

1. Position the paver with the screed in the required width parallel to the reference wire on the mat to be paved. 2. Loosen the clamp between the outrigger (6) and the indicator tube (7). Pull out the indicator tube (7) to the required width. 3. Then retighten the clamp. 4. Loosen the fastening screw (11) and insert the angular tube (8) into the indicator tube (7). Set the height of the angular tube (8) so that the two chains (9) dangle either side of the reference wire. 5. Now tighten up the fastening screw (11). The clamps (10) holding the chains (9) on the angular tube (8) can be repositioned on the tube as required. 6. Set the angular tube (8) so that it points outwards and to the front of the paver. The angle between the indicator tube (7) and the angular tube (8) should be approx. 105 degrees. If you work with only one chain (9), then this chain must continuously dangle along the reference wire between the paver and the wire itself.

ELECTRONIC LEVELLING SYSTEM Instructions for setting up and operating the levelling system are contained in the documentation for your particular system.


3-51

Chapter 3

OPERATION

PAVING SETTING THE OPERATING MODE AUTOMATIC Illustration 34

We recommend the "Automatic" operating mode for paving work. 1. Move the toggle switches on the control panel to the following positions to set up the "Automatic" mode:

3-52

•

Toggle switch „Vibration“ (A7) to „AUTO“

•

Toggle switch „Tamper“ (A8) to „AUTO“

•

Toggle switch „LH Conveyor“ (A34) to „AUTO“

•

Toggle switch „RH Conveyor“ (A19) to „AUTO“

•

Toggle switch „LH Auger“ (A33) to „AUTO“

•

Toggle switch „RH Auger“ (A18) to „AUTO“

•

Toggle switch „RH Auger mode“ (A32) to „PROP“

•

Toggle switch „LH Auger mode“(A17) to „PROP“


OPERATION

Chapter 3

MAT THICKNESS, ADJUSTING The mat thickness is set on the tow points.

!

WARNING

The LH and RH screed towing arms must have almost the same setting. The difference in the mat thickness must not exceed 10 cm. Otherwise the screed will be distorted and damaged. Illustration 35

When paving, the tow points must not ride against the upper or lower limit stops. Otherwise, the hydraulic circuits for hopper open/close and screed raise/lower would no longer function. If the tow points ride against the limit stops during paving work, the position of the screed towing arms must be altered relative to the paving screed so that the tow points have adequate space to move between the limit stops. Further information is contained in the operating manual for the screed. 1. Ensure the toggle switch for the "levelling system" (A35) is not switched to position „1“; i.e. position „MAN“ or position „AUTO“. 2. The tow points on both towing arms are adjusted using the toggle switch (A16) "RH tow point" and (A37) "LH tow point". •

Increasing the mat thickness: Move the toggle switches (A16 and A37) for the RH and LH tow points upwards in the direction of the arrow until the required mat thickness is reached.

•

Reducing the mat thickness: Move the toggle switches (A16 and A37) for the RH and LH tow points downwards in the direction of the arrow until the required mat thickness is reached.

Remarks: Alternatively, the tow points can be adjusted on the external control panel using the button switch for increase mat thickness (B1, 220Page) and for reduce mat thickness (B2, 220Page).


3-53

Chapter 3

OPERATION

SCREED FLOATING MODE The correct screed floating mode is an important prerequisite for paving a perfect mat.

!

WARNING

To avoid accidents, completely lower the screed before switching to the floating mode. Illustration 36

1. Place square timbers or paving material underneath the screed. This will set the screed to the required mat thickness.Add the degree of mix slump caused by rolling. 2. Move the toggle switch (A29) "screed floating mode" to the "O" position. 3. Move the toggle switch (A31) "screed raise/lower" downwards to lower the screed onto the timbers. 4. Move the toggle switch (A29) "screed floating mode" to the position "1". The screed is now in the floating mode. 5. Ensure the control lamp (A30) "screed floating mode" illuminates. If this is not the case, the screed is not fully lowered and is in the hydraulically blocked position. An uneven mat would result if the machine paved with the screed in this position. Therefore, manually lower the screed further downwards.

3-54


OPERATION

Chapter 3

NOTICE We advise against starting paving work with a hydraulically blocked screed and then switching to the floating mode after sufficient material is forced underneath the screed. Normally, the screed would then not float.


3-55

Chapter 3

OPERATION

SCREED HEATING, ON / OFF

!

DANGER

There is a danger of explosions caused by escaping gas. Keep all sparks and naked flames far away from the gas heating components. Ensure there is adequate ventilation. If a gas leakage occurs, immediately close the valves on the gas bottles (turn the valve clockwise because it has a left-hand thread). The gas bottles for the screed heating must be safely secured against falling over and be protected from the sun at ambient temperatures above 20° C (fit the gas bottle canopies). Paving screeds can be heated by propane gas or Diesel fuel (only for Variomatic screeds) heating systems. Operating instructions for the propane gas or Diesel fuel heating system can be taken from the operating manual for your particular paving screed. There is a separate operating manual for the temperature controlled gas blower heating system (Thermo-Control). Strictly observe all locally prevailing directives and laws for operating the heating system on your paving screed. Some of the connections on the propane gas heating system have lefthanded threads. These can be recognised by a groove in all six surfaces on the union nuts. At the end of paving work, close the valves on the gas bottles, the distributor and on the gas burners. Before transporting the paver, close the valves on the gas bottles, remove the gas hose with pressure reducer and fit the protective caps on the gas bottles.

3-56


OPERATION

Chapter 3

PAVING IN THE AUTOMATIC MODE

!

WARNING

Depending on the ambient temperature, the hydraulic drives must warm up for 2 to 5 minutes before starting paving work. Govern the engine speed with the throttle lever (A38). Before paving, ensure all protective guards and devices are correctly installed and fully functional on the paver and screed. Illustration 37

1. Move the engine throttle lever (A38) to the maximum speed. 2. Move the toggle switch (A13) to the low paving speed stage (L). 3. Turn the steering potentiometer (A26) to the centre zero position. 4. Turn the speed potentiometer (A9) to the required travelling speed. Remarks: Altering the speed during paving work will alter the compaction of the paving material and consequently the mat thickness. The speed selected depends upon the paving width, the mat thickness and the kind of paving material. 5. Ensure there are no persons in the danger zone around the paver.


3-57

Chapter 3

OPERATION

6. As soon as you move the drive lever (A25), the spring loaded brake will be released and the paver will start moving. •

Push the drive lever (A25) forwards and the paver will travel forward.

•

Return the drive lever to the centre neutral position to stop the paver.

7. Use the steering potentiometer (A26) to steer the paver.

PAVING MATERIAL PRONE TO SEGREGATION Experience has shown that material in the area of the hopper wings has a significantly higher portion of coarse grains. This segregated material should not be paved on its own because areas of coarse grains would occur in the mat. Close the hopper wings and allow the segregated material to flow onto the conveyors just before a new truck load of paving material is dumped in the hopper. When doing this, the conveyors remain switched off until the hopper has been filled with fresh paving material. The fresh paving material together with the segregated material can now be conveyed to the augers. In this way, a mix segregation can be avoided. The conveyors should not run empty when changing dump trucks; forin fact, a layer of material should remain in the hopper. If possible, the head of material in the auger channel should have a uniform height across the entire width of the screed. Depending on the thickness to be paved, this is achieved by lowering the augers and removing an auger flight from those areas where there is not enough material. Under certain conditions and especially at the outer screed areas, every second flight must be removed. In this case we recommend that every second remaining flight should be mounted offset by 180° on the auger shaft; this will give a uniform load on the auger shaft. The conveyor and augers must be operated in the automatic mode. The sensors and control switches must be so adjusted to reach a uniform head of material and the augers are only subject to minor speed alterations. Run the tampers and vibrators at maximum speed when paving base courses. When paving wearing courses, slightly reduce the tamper speed to prevent the screed loosing its floating behaviour on account of a too high compaction. If the previously mentioned measures do not prevent a concentration of coarse grain in front of the augers and which reaches to the top of the mat being paved, the rear wall of the basic machine in the area of the auger outer bearings must be extended downwards by fitting steel plates or hard rubber sheeting to avoid the coarse grains rolling to the front. If necessary, these steel plates or hard rubber sheeting must be fitted across the entire width of the screed (these parts do not belong to the paver's standard range of supply). Even at higher ambient temperatures, the screed must be permanently heated if material with a temperature of 150° C and less is being paved. However, try to have the paving material delivered with a mix temperature of 160 - 170° C. If mix segregation occurs as an open surface structure in the middle area of the screed when paving thicker mats, replace the first auger helical on one side with a helical with an opposite pitch. This will force more paving material underneath the auger drive case and rectify the mix segregation.

MAT THICKNESS IS NOT CORRECT The screed's angle of attack must be altered by turning the rear turnbuckles if a significant dif-

3-58


OPERATION

Chapter 3

ference occurs between the mat thickness set on the paver (value on the tow point mat thickness scales) and the actual thickness of the mat being paved. The turnbuckles are set to a value of "0" in the factory and increasing this value will achieve a thicker mat. We recommend that the rear turnbuckles are not adjusted for paving mat thicknesses up to approx. 10 cm. This means, that the screed's angle of attack will be adjusted by the tow points to the mat thickness. Rule of thumb: Value on the tow point thickness scales = 1.5 x the mat thickness. Further instructions for adjusting the screed are contained in the screed's operating manual.

TOW POINT SINKS DOWN DURING PAVING WORK Ball cocks are installed on the hose connections on the piston rod side of the levelling cylinders and with these ball cocks, the cylinders can be blocked against sinking downwards. The ball cock must be closed if the automatically operated double check valve leaks and allows the screed to sink downwards at the tow points when paving. The ball cocks must remain open when paving with an automatic levelling system to control the mat thickness.

CONVEYING THE PAVING MIX TO ONE SIDE This section describes how to convey a uniform head of material to both sides of the screed just before finishing paving work even though the hopper only has material on one side. Likewise, additional material requirements on one side caused by changes in the cross section profile can be compensated by reversing one of the augers. 1. Conveying the paving material with both augers: •

to the LH screed side: Move the toggle switch A21 "auger reverse rotation" to the left (27Page).

•

to the RH screed side: Move the toggle switch A21 "auger reverse rotation" to the right (27Page).

•

to switch off: Move the toggle switch A21 "auger reverse rotation" to the centre position (27Page).


3-59

Chapter 3

OPERATION

PAVING MATERIAL NOT CONVEYED FAST ENOUGH The auger can be overmodulated if not enough paving material is being conveyed. The auger will then rotate at maximum speed. For this function, the button B7 for "STOP material flow" must be pulled upwards (27Page). 1. Rotating the auger at maximum speed: •

LH Auger: Keep the button switch B3 pressed on the LH external control panel to overmodulate the auger (27Page).

•

RH Auger: Keep the button switch B3 pressed on the RH external control panel to overmodulate the auger (27Page).

SETTING THE PRESSURE ON THE SCREED ASSIST If required, a variable pressure between 10 and 50 bar can be applied to the screed transport cylinders. This pressure counteracts the weight of the screed and prevents it sinking into paving material with a low bearing capacity. This option does not effect the screed's floating behaviour; the screed will bear down on the material with a reduced load. Illustration 38

The control valve is located inside the LH side door on the paver's rear wall. The pressure is adjusted as follows (Pos. 1 refers): •

Loosen the lock nut, 24 across flats

•

Turn the Allen screw: Clockwise to increase the pressure Anti-clockwise to reduce the pressure

•

Thereafter, tighten the lock nut.

Check the pressure on the test connection (2).

3-60


OPERATION

Chapter 3

DAILY PROCEDURE AT THE END OF PAVING WORK 1. Refuel and clean the paver (Chapter 3 “Refuelling the Paver”, Page 3-30). 2. Drive the paver to the parking area. Ensure the paver does not cause an obstruction. 3. Return the drive lever (A25, 27Page) to the centre zero position. 4. Lower the screed to the ground (Chapter 3 “Screed Transport Lock”, Page 336). 5. With the conveyors and augers running, press the illuminated button switch A10 „rapid lubrication“ (, 27Page). 6. Do not switch off the engine under full load; let it run without load at idling speed for approx. 5 minutes to cool down. 7. Switch off the engine, remove the ignition key and lock the control panel. 8. Close the valves on the gas bottles and switch off the screed heating (Chapter 3 “Screed Heating, ON / OFF”, Page 3-56). 9. Switch off the power supply with the battery master switch and remove the red plastic key (Chapter 3 “Switching the Power Supply ON and OFF”, Page 3-7). 10. Ensure all compartments and covers are closed and if possible, securely locked. 11. Clean all parts and components which have been in contact with paving material: •

Bituminous material: Use the optional spray cleaning system.

•

Mineral aggregates, dry-lean concrete and similar materials: Use a water hose.

12. Clean the paver. In particular, remove all dirt, water or ice from the operator's platform and in the vicinity of the external control panels which may pose a slip hazard. 13. If the paver is not equipped with the optional central lubrication system, grease the auger bearings, the auger seals as well as the drive shafts and idler shafts for the conveyors (Chapter 4 “Grease Points”, Page 4-29).


3-61

Chapter 3

OPERATION

LOADING AND TRANSPORT LOADING BY CRANE

!

DANGER

Suspended loads are an increased hazard leading to serious injuries and fatal accidents. Only use hoisting and lashing chains and slings which comply with all prevailing regulations. Ensure that no persons are underneath a suspended machine. Strictly observe the following instructions to avoid serious personal injury and damage to the machine when loading and transporting the paver:

3-62

•

When choosing hoisting and lashing chains and slings, take the weight of the paver (technical data refers) and the paving screed (refer to the screed's operating manual) into consideration.

•

Chains and slings must comply with all locally prevailing accident prevention regulations and must have sufficient lifting capacity to take the weight of the machine.

•

Only fasten hoisting and lashing slings and chains to the hoisting and lashing points provided on the paver.

•

Observe all locally prevailing laws, regulations and the traffic code when driving or transporting the paver on public roads.

•

Transport and loading work may only be carried out by qualified and authorized personnel. Only experienced personnel should be assigned for attaching the crane hooks to the machine and instructing the crane operator. The person giving the instructions must be clearly seen by the crane operator.

•

Raise the augers to their highest position before transporting the paver.Chapter 3 “Auger Height Adjustment”, Page 3-42

•

Remove all loose objects from the paver before loading it by crane.


OPERATION


1. Close and lock the hopper wings (Chapter 3 “Hopper Wings, Open and Close”, Page 3-36). 2. Retract the operator's platform, seta console and sun roof and remove the exhaust pipe (Chapter 3 “Setting up the Operator's Platform”, Page 3-8). 3. Remove the gas bottles from the paver (only applies to pavers fitted with the optional gas heating).Chapter 2 “Screed Heating System (Option)”, Page 2-30 4. Dismantle any screed extensions to reach the specified transport width (refer to the operating manual for your screed); raise and secure the screed in the transport lock (Chapter 3 “Screed Transport Lock”, Page 3-36). Retract the Variomatic screed to the basic width. 5. Remove all components from the paver which protrude beyond the basic width. 6. Switch off the engine, lock all compartments and switch off the power supply with the battery master switch (Chapter 3 “Switching the Power Supply ON and OFF”, Page 3-7). 7. Check all fluid levels so that they do not escape when the machine is tilted. 8. Remove all loose objects from the paver. 9. Lower the sun roof (Chapter 3 “Raising and Lowering the Sun Roof”, Page 3-9). 10. Use wheel chocks to secure the front and rear wheels of the transport vehicle. 11. Attach the crane slings to the hoisting points marked on the paver (illustration refers).


3-63

Chapter 3

OPERATION

12. The load suspension point (Fz) must be brought to a position vertically above the paver's centre of gravity (Fg). •

The paver's centre of gravity (Fg) depends upon the type of screed fitted to the machine.

•

Basically, the paver's centre of gravity is between the first and second track roller in front of the crawler drive assembly.

13. Place dismantled screed extensions or similar heavy objects in the hopper to balance the weight of the paver when hoisting. Ensure the items placed in the hopper are safely secured against moving. 14. Cordon off the loading area and ensure no persons are in the danger zone. 15. Carefully hoist the paver with the crane and check the lashing points and balance. Only hoist the paver onto the vehicle after checking that all crane slings are correctly attached and the machine is not out of balance. 16. Position the paver on the vehicle so that it is exactly in the middle of the loading bed. 17. Securely lash the machine as soon as it is on the loading vehicle. (refer to ”Lashing the Machine on the Vehicle”, page 3-66).

3-64


OPERATION

Chapter 3

LOADING ON A VEHICLE WITH RAMPS 1. Close and lock the hopper wings (Chapter 3 “Hopper Wings, Open and Close”, Page 3-36). 2. Retract the operator's platform, seat console and sun roof. Remove the exhaust pipe (Chapter 3 “Setting up the Operator's Platform”, Page 3-8). 3. Remove the gas bottles from the paver (only applies to pavers fitted with the optional gas heating).Chapter 2 “Screed Heating System (Option)”, Page 2-30 4. Dismantle any screed extensions to reach the specified transport width (refer to the operating manual for your screed); raise and secure the screed in the transport lock (Chapter 3 “Screed Transport Lock”, Page 3-36). Retract the Variomatic screed to the basic width. 5. Remove all components from the paver which protrude beyond the basic width. 6. Check all fluid levels so that they do not escape when the machine is tilted. 7. Remove all loose objects from the paver. 8. Park the transport vehicle on firm and even ground and secure the front and rear wheels with wheel chocks. 9. Keep the bed of the loading vehicle free from clay, oil, mud, ice and frost which are a slip hazard. 10. Use suitable loading ramps. Ensure that the loading ramps have sufficient bearing capacity, and low ramp angle (< 25%), the correct height and width and a non-skid surface. 11. Drive the machine up the ramp in a straight line so that it does not slide or tilt off the side of the ramp. 12. Position the paver on the vehicle or low loader so that it is exactly in the middle of the loading bed. 13. Stop the engine and lock all compartments. 14. Securely lash the machine on the loading bed (refer to ”Lashing the Machine on the Vehicle”, page 3-66). 15. Lower and secure the sun roof (Chapter 3 “Raising and Lowering the Sun Roof”, Page 3-9). 16. Switch of the power supply with the battery master switch (Chapter 3 “Switching the Power Supply ON and OFF”, Page 3-7).


3-65

Chapter 3

OPERATION

LASHING THE MACHINE ON THE VEHICLE

!

DANGER

Only use hoisting and lashing chains and slings which comply with all prevailing regulations. Strictly observe the following instructions to avoid serious personal injury and damage to the machine when loading and transporting the paver: •

When choosing lashing chains and slings, take the weight of the paver (technical data refers) and the paving screed (refer to the screed's operating manual) into consideration.

•

Chains and slings must comply with all locally prevailing accident prevention regulations and must have sufficient strength to take the weight of the machine.

•

Only fasten the lashing slings and chains to the lashing points provided on the paver.

•

Observe all locally prevailing laws, regulations and the traffic code when driving or transporting the paver on public roads. Illustration 40

1. Release and lower the screed from the transport locking device (Chapter 3 “Screed Transport Lock”, Page 3-36). During transport, the screed must be completely lowered and resting on the bed of the transport vehicle. 2. Finally, securely lash the machine on the bed of the loading vehicle using suitable chains and slings in compliance with your locally prevailing regulations and use wheel chocks if necessary. Attach the chains and slings to the lashing points marked on the paver.

3-66


CHAPTER 4 - MAINTENANCE


4-1

Chapter 4

MAINTENANCE

MAINTENANCE Only use genuine spare parts to uphold warranty claims and to achieve a reliable machine operation as well as an optimum paving output.

IMPORTANT INSTRUCTIONS

!

WARNING

Sudden and unexpected movements of the machine and moving parts can cause injuries. Before working on the paver, lower the screed (it must completely rest on the ground) and switch off the engine. Improper maintenance can lead to danger. Thoroughly read Chapter 1 “Safety”, Page 1-2 before performing any maintenance and repair work on the paver. •

The procedures for starting and stopping the paver as well as the instructions for maintenance work described in the operating manual must be strictly observed when performing any work which affects the operation, configuration and adjustments on the paver and its safety devices as well as maintenance, servicing and repair work.

•

Ensure the area for maintenance work is adequately marked.

•

The paver must be secured against unintentional starting as follows if it must be completely shut down for maintenance and repair work: — Remove the ignition key and the key for the battery master switch. — Fasten a tag on the operator's platform with the text: „Maintenance work ! Do not start the machine !

4-2

•

Only carry out maintenance and repair work after the paver has been parked on firm and level ground and safely secured against unintentional movements.

•

Exercise extreme care to avoid accidents if lifting devices are attached to individual parts and larger assembles for removing them from the machine. Only use lifting devices which are in a perfect working condition and have the required lifting capacity. Never work or stand below suspended loads.

•

Always use the correct tools and workshop appliances for maintenance and repair work on the machine.

•

Always use suitable ladders or working platforms for assembly work on components higher up on the machine. Never use components for climbing onto the machine.

•

All grip bars, steps, handrails, platforms, decks and ladders must be kept free from mud, dirt, snow and ice.

•

Before carrying out any maintenance and repair work, clean the machine, especially connections and threaded fastenings from oil, fuel and remnants of preservation grease. Never use aggressive cleaning solvents. Always use non-fibrous cleaning


MAINTENANCE

Chapter 4

cloths. •

Before cleaning the machine with water, steam jets (high pressure cleaners) or other cleaning agents, close or seal with adhesive tape all doors, hatches and openings which for safety or functional reasons must be protected against water, steam or cleaning solvents. Exercise special care with electric motors and electronic equipment.

•

Ensure that temperature feelers do not come into contact with hot cleaning solvents when cleaning the machine.

•

Remove all covers and adhesive tape after cleaning the machine.

•

After cleaning the machine, check all lines for fuel, grease and hydraulic fluid for leakage, loose connections, chafing and damage. Immediately repair or renew all faulty parts.

•

Tighten all threaded connections previously loosened for maintenance and repair work.

•

After completion of maintenance and repair work, replace and check all safety devices previously removed.

•

Ensure that all consumables and spare parts have been correctly disposed of in accordance with your locally prevailing environment regulations.

•

Avoid carrying out maintenance, cleaning and inspection work when the engine is running.

•

Never refuel the machine if the engine is running, near naked flames and do not smoke.

•

Do not alter the engine adjustments. The details on the engine manufacturer's identification plate must correspond to the engine adjustments.

•

Always replace lost warning signs and symbols.The position and the part numbers of the warning signs and symbols can be found in the spare parts list.

•

By using genuine spare parts, you will maintain the operating safety and optimum machine performance guaranteed in the warranty conditions.

•

Switch off the power supply with the battery master switch before working on the electrical system or carrying out any welding work on the machine (Chapter 3 “Switching the Power Supply ON and OFF”, Page 3-7).


4-3

Chapter 4

4-4

MAINTENANCE

•

Ensure the battery cover is removed when connecting jump starter cables and battery chargers to the battery (avoid an accumulation of battery gasses). Battery gasses can be ignited to an explosion by sparks.

•

The battery charger MUST be switched off when connecting it to the battery.

•

Only use genuine fuses with the specified amperage. Immediately switch off the paver if problems occur in the electrical system.

•

Any work on the machine's electrical system and equipment may only be performed by a trained assistant electrician or a similarly trained person whereby they are supervised and controlled by a fully trained and qualified electrician. This work must be carried out in accordance with your locally prevailing electro-technical regulations and directives.

•

If required by regulations, the power supply to the paver's sub-system on which inspection, maintenance or repair work is to be carried out, must be interrupted.

•

Before starting work, ensure the sub-system, is disconnected and at zero potential and earthed or short circuited. Furthermore, all live parts and components must be isolated.

•

The paver's electrical equipment must be checked and examined at regular intervals. Faulty parts such as loose connections or charred wiring must be immediately renewed.

•

Welding, torch cutting and grinding work may only be carried out on the paver after express permission has been obtained because this work can cause explosions and fires.

•

Before commencing any welding, torch cutting or grinding work, the paver and its surrounding area must be cleaned and free from all dust and inflammable materials and the working area must be adequately ventilated (danger of explosions - check all wiring and hoses for leakage and visual damage). Any damage found must be immediately repaired. Escaped oil is a fire risk and health hazard.

•

Hydraulic hoses must be regularly checked and immediately renewed if they are found to be chafed, cracked, brittle, deformed or have visible bulges, leakages, loose connections or any other damage which impairs their function or durability.

•

Never carry out any work on the hydraulic lines when the engine is running and the system is under pressure. Hydraulic fluid is still under pressure even though the engine has been switched off.

•

Before starting any repair work, all systems and the pressure lines to be removed (hydraulic system, compressed air system) must be depressurised in accordance with the instructions for the particular components.

•

Never commence any work on hydraulic hoses and connections until the pressure has been properly relieved from the system.


MAINTENANCE

Chapter 4

•

Wait until the hydraulic fluid has cooled down before disconnecting any hydraulic hoses. Hot hydraulic fluid will cause serious burns and scolding.

•

Do not use your hand to check for leakage in the hydraulic system. Use a piece of cardboard and wear protective gloves and goggles.

•

Even a small amount of hydraulic fluid can cause serious injuries and fatal accidents. Immediately remove hydraulic from your skin. Immediately go to a doctor if hydraulic fluid gets into your eyes, you swallow or breath it.

•

Hydraulic lines must be correctly routed and properly connected. Ensure the hydraulic connections are not swapped with each other. The connections, length and quality of the hydraulic lines must comply with all technical requirements.

•

Strictly observe the product specific safety regulations when handling oil, grease and other chemical substances.

•

Exercise special care when handling hot materials (danger of burning and scolding).

BEFORE STARTING MAINTENANCE WORK Ensure the following points are observed before starting maintenance work: 1. Park the paver on firm and even ground. Cordon off the working area. 2. Switch off the engine and let it cool down. 3. Switch off the power supply with the battery master switch (Chapter 3 “Switching the Power Supply ON and OFF”, Page 3-7). Remarks: The power supply should not be switched off to check certain faults. 4. After stopping the engine, wait until the hydraulic oil pressure has dropped before starting maintenance work on the hydraulic system. 5. Before starting maintenance work, clean all threaded connections, caps and plugs etc with a non-flammable and non-toxic cleaning solvent so that dirt cannot penetrate the system during work.


4-5

Chapter 4

MAINTENANCE

HANDLING HAZARDOUS MATERIALS 1. Have suitable and lockable containers at hand for draining off fluids. Ensure no fluids are spilled. Remove any spilled hazardous materials and dispose of them in an environmentally manner. 2. Dispose of all used fluids, lubricants, filters and batteries etc in accordance with your locally prevailing environment regulations.

WELDING WORK ON THE PAVER Disconnect the following before welding on the paver: •

Electronic travel drive

•

Levelling system

•

Battery master switch

•

All other electronic equipment

•

Battery

•

Alternator

Furthermore, the earth terminal on the welding appliance must be clamped in the immediate vicinity of the part to be welded. The welding current must not pass through bearings. Reconnect the above components in the opposite sequence on the completion of welding work.

FIRST OIL CHANGE Carry out the following maintenance work after running in a new machine for approx. 50 operating hours. Thereafter, carry out the regular maintenance intervals specified on the following pages. 1. Change the engine oil and oil filters.

4-6


MAINTENANCE

Chapter 4

MAINTENANCE CHART The maintenance chart contains the components which must be regularly serviced and their maintenance intervals. All components listed under a maintenance interval should be regularly serviced. These intervals are based on the average operating conditions and manufacturer's recommendations. The maintenance intervals must be shortened if the machine is operated under extremely difficult, dusty or humid conditions (more frequent maintenance is required). In the following table, the maintenance intervals specified by the manufacturer may deviate from those intervals specified by the engine manufacturer but must still be adhered to. When performing the work for a maintenance interval, you must also perform the work for the previous intervals. For example, if you carry out a yearly maintenance, you must perform the work for the yearly intervals and also for the half-yearly, quarterly, weekly and daily maintenance intervals.

NOTICE Please refer to the separate documentation for the maintenance work for the screed and engine. The maintenance work marked with an asterisk * must be carried out together with the first service at 100 operating hours. Thereafter, the specified maintenance intervals apply.

Table 5: Maintenance Chart Maintenance Work

Further Information

As required Tighten threaded connections

410Page

Charge the battery

414Page

Clean the sieve in the fuel tank filler neck

330Page

Clean the filler neck sieve for the emulsion spraying system

226Page


4-7

Chapter 4

MAINTENANCE

Maintenance Work

Further Information

EVERY 10 OPERATING HOURS (DAILY) Clean the machine and visual check

410Page

Check the grease level for the central lubrication system

332Page

Grease the conveyor drive shaft

429Page

Grease the auger drive case seal and all auger bearings

429Page

Check the engine oil level and top up if necessary

411Page

Check the hydraulic oil level

436Page

Check the pump distributor gear

420Page

Check the travel drive transmissions

420Page

Functional test on the warning devices (horn, lights, controls and instruments etc)

–

EVERY 40 OPERATING HOURS (WEEKLY) Grease all drive chains

428Page

EVERY 100 OPERATING HOURS Check the oil level in the travel drive transmissions

433Page

Check the sag on the conveyor drive chains

421Page ff

Check the sag on the conveyor chains

421Page ff

Check the sag on the auger drive chains

421Page ff

Check the auger bearing protectors for wear Drain the water out of the auger drive case

– 421Page ff

Check the oil level in the pump distributor gear

434Page

Check the battery terminals

414Page

Drain the water from the preliminary fuel filter

421Page

Check the coolant level and top up if necessary

412Page

EVERY 250 OPERATING HOURS Clean the hydraulic oil cooler and radiator

4-8

419Page


MAINTENANCE

Chapter 4

Maintenance Work

Further Information

EVERY 500 OPERATING HOURS Grease the slip guides and guide rollers on the towing arms

429Page ff

Grease idler bearing

429Page ff

Diesel engine - oil change *

Engine handbook

Diesel engine - change the oil filter cartridge *

Engine handbook

Diesel engine - tension the V-belt *

Engine handbook

Change the hydraulic oil filter *

415Page

EVERY 1000 OPERATING HOURS Change the fuel filter cartridge

Engine handbook

Change the air filter cartridge

Engine handbook

Check the bolts on the hydraulic cylinders for tight fitting and wear

–

Check the cooling system for leakage

–

Change the filter cartridges for the levelling cylinders and augers

416Page

Change the filter cartridge for the travel drive and tamper drive

417Page

Clean the vent filter on the hydraulic oil tank

418Page

EVERY 1500 OPERATING HOURS Change the pump distributor gear oil *

434Page

Change the transmission gear oil *

433Page

EVERY 2000 OPERATING HOURS Change the engine coolant

Engine handbook

Change the hydraulic oil *

436Page

Change the vent filter on the hydraulic oil tank

418Page

* First service at 100 operating hours


4-9

Chapter 4

MAINTENANCE

MAINTENANCE WORK

!

CAUTION

The engine must be switched off when carrying out the following maintenance work.

MACHINE (GENERAL) Cleaning the Machine

When cleaning the machine and machine components with a hose or high pressure cleaner, water and other impurities can penetrate bearings, seals and other components in the system.

NOTICE When using high pressure cleaners, ensure that water or steam does not penetrate electrical components and control systems. Do not use any aggressive cleaning solvents which may cause damage to painted surfaces. Let the engine run warm after washing the machine. This will allow the engine components and electrical connections to dry quicker. Lubricate all grease nipples after cleaning the machine. Before Cleaning

1. Remove all paving material stuck to the machine. After Cleaning:

1. Remove all material used to prevent water penetrating the machine. 2. Immediately lubricate all grease nipples. 3. Check all air intakes for deposits of dirt which may constrict the flow of air and ensure a free and unobstructed air intake. 4. Check all fastenings on the air filter and repair any damage found. 5. Check all hoses for cracks, wear and damage and renew them if necessary. Tighten threaded connections

1. Correctly tighten all loose nuts and threaded connections found during daily maintenance. (refer to ”Torques for threaded connections”, page 8-2.) 2. Renew any loose self-locking nuts if necessary.

4-10


MAINTENANCE

Chapter 4

DIESEL ENGINE

NOTICE Instructions for upkeep and maintenance procedures for the Diesel engine as well as details of the required consumables are included in the appended engine manufacturer's handbook. Check the engine oil level

!

CAUTION

Wrong oil level. The wrong oil level will damage the engine. Switch off the engine and weight for about 10 minutes for the oil to settle in the sump. Illustration 6:

1. Remove the oil dip stick (1). 2. Wipe the dip stick (1) dry with a non-fibrous cloth. 3. Replace the dip stick (1) into the engine. 4. Remove the oil dip stick (1). Check the oil level on the dip stick. •

If the oil level is between „max“ and „min“: the level is OK.

•

If the level is above „max“: Drain off oil to the correct level. (refer to ”Oil Change, Diesel Engine”, page 4-38)

•

If the level is below „min“: Add oil through the filler cap (2) to the correct level.

5. Replace the dip stick into the engine.


4-11

Chapter 4

MAINTENANCE

Fuel filter - draining off the water

Illustration 7:

1. Open the cock (1) to drain off the condensed water. 2. Close the cock (1).

4-12


MAINTENANCE

Chapter 4

ELECTRICAL SYSTEM

!

WARNING

Batteries contain acid which can lead to injuries. Battery vapour can ignite and explode. Battery acid will cause injuries if it comes into contact with your eyes and skin. Do not smoke when checking the battery acid. Avoid battery acid touching your eyes and skin. Thoroughly rinse your eyes and skin with clean water splashed with battery acid.

NOTICE Information on battery upkeep and maintenance is contained in the engine handbook. The Diesel engine is equipped with a 28 V three-phase alternator. Due to the characteristics of the three-phase alternator, special instructions for system with three-phase alternators must be observed. •

Observe the correct polarity when connecting the batteries otherwise the diodes will be destroyed.

•

To determine whether a DC dynamo is supplying current, you can lightly touch the earth. NEVER test a three-phase alternator in this way otherwise the semiconductors will be damaged.

•

The preexcitation of the three-phase alternator is effected by the battery via the battery charging lamp (A5c, 27Page). Therefore, a faulty charging lamp must be immediately renewed to ensure a correct excitation. Illustration 8


4-13

Chapter 4

MAINTENANCE

Charge the battery

1. The engine and ignition must be switched off. 2. Before disconnecting the battery, all electronic equipment must be disconnected from the system, e.i. al plug connections must be unplugged. 3. Loosen and remove the terminal clamps before charging the battery. For safety reasons, first remove the negative ( - ) terminal and then the positive ( + ) terminal. 4. After charging the battery, connect the terminal in the opposite sequence, i.e. first the positive ( + ) and then the negative ( - ) terminal. Observe the correct polarity when connecting the terminals. 5. Identification tags with numbers are attached to all ends of the wires in the cable loom and these numbers correspond to the numbers on the machine's wiring diagram. A further aid to identification are the colours of the wires specified on the wiring diagram. Greasing the battery terminals

1. Clean the battery terminals. 2. Check the terminal clamps for tightness. 3. Apply a thin film of battery terminal grease to the terminals to prevent corrosion.

4-14


MAINTENANCE

Chapter 4

HYDROSTATIC SYSTEM Extreme cleanliness is a basic requirement for all maintenance and repair work on hydraulic systems. Used oil, sand, dirt and metal chippings in hydraulic systems not only impair the function and service life of the components, they also cause damage and eventually a complete breakdown of the system. Regularly check the hydraulic system for leakage and tight fitting of all threaded connections.

!

CAUTION

All work on the hydraulic system such as tightening threaded connections, exchanging filters, oil changes and renewing components etc. (with the exception of checking the valve settings) may only be carried out with the system completely depressurised, i.e. with the engine switched off. Use clean plastic plugs to close the ends of any hydraulic hoses or tubing which must be disconnected. Do not use cleaning cloths or cotton waste to close hoses and tubes. Illustration 9

When replacing hydraulic pumps and motors, the oil drain case must be filled with clean hydraulic oil before putting them back into operation. Add oil through the drain case oil connection (1). Before putting the system back into operation, we recommend to flush the hydraulic lines; if necessary, they must be dismantled . A second possibility is to fit a high pressure filter with a filter mesh of 0.01 mm (10 um) into the appropriate circuit instead of the hydro motor and filter the circuit for approx. 5 to 10 minutes (check the filter's direction of flow).


4-15

Chapter 4

MAINTENANCE

High Pressure Filter for the Levelling Cylinders and Augers

Illustration 10

The filter cartridges on the high pressure filters for the levelling cylinders (1) and the augers (2) must be changed for the first time at 125 operating hours and thereafter every 1000 operating hours or at least once a year.

4-16


MAINTENANCE

Chapter 4

Feed Pressure Filter for the Travel Drive and Tamper Drive (only for VDT and VDT-V Screeds)

Illustration 11

The hydraulic oil is filtered by the feed pressure filters (3) installed on the pressure side of the feed pumps. The feed pressure filters do not have a bypass which means that if the filter is blocked, no unfiltered oil enters the closed circuit. Instead of a bypass, the filters have integrated over pressure valves which open and allow the hydraulic oil to flow back to the tank if the difference in pressure between filter inlet and filter outlet is more than 5 bar. With an increasing amount of dirt in the filter or with a too high oil viscosity at low temperatures, the displacement of the variable pump in the main circuit will be delayed or there will be no displacement at all. As a consequence: the paver's travel drive will lag or the paver will not travel at all. If this is due to cold oil, let the hydraulics run warm to reach normal operating temperature. If this is due to a dirty filter, immediately change the filter cartridge. Change the filter cartridge for the first time at 125 operating hours and thereafter every 1000 operating hours or at least once a year.

!

CAUTION

After every filter change, run the Diesel engine for approx. 5 minutes at idling speed, i.e. max. 800 1/min to build up the feeding pressure.


4-17

Chapter 4

MAINTENANCE

Cleaning the Vent Filter

Illustration 12

A vent filter is integrated in the filler cap for the hydraulic oil tank. The gauze must be cleaned every 500 operating hours with compressed air; thereafter, moisten the gauze with a little clean hydraulic oil.

4-18


MAINTENANCE

Chapter 4

Cleaning the Hydraulic Oil Cooler and Radiator

Illustration 13

To ensure an adequate cooling, the hydraulic oil cooler and engine radiator (2) must be cleaned every 250 operating hours. To do this, soak them with a cold cleaning solvent and spray them with a strong jet of water; better still, use a steam pressure cleaner. Access to the radiator is gained through the duct at the rear of the hopper (1). Carry out the cleaning work as described in the engine manufacturer's handbook.

NOTICE When operating under very dusty conditions, it may be necessary to shorten the cleaning intervals if the hydraulic oil temperature or the engine temperature unduly rises.


4-19

Chapter 4

MAINTENANCE

TRANSMISSION GEARS Check the pump distributor gear

Illustration 14

•

Open and arrest the deck plate and side door.

•

Check the tubing, hoses and transmission gear daily for leakage.

•

Regularly check all threaded connections for tightness and visual damage.

•

Check the oil level and/or change the oil (refer to Chapter 4 “Oil Change, Pump Distributor Gear”, Page 4-34).

Check the travel drive transmissions

Illustration 15

4-20

•

Check the transmission gears for leakage daily.

•

Regularly check all threaded connections for tightness and visual damage.

•

Check the oil level and/or change the oil (refer to Chapter 4 “Oil Change, Transmission Gears”, Page 4-33).


MAINTENANCE

Chapter 4

DRIVE CHAINS AND V-BELTS When performing maintenance on drive chains and V-belts, look for apparent damage and renew all faulty parts. Check at retension the engine V-belts one day after commissioning the new paver. Check the V-belt tension once again after one week of operation and then at intervals of approx. four weeks. The narrow V-belts require tension to transmit power but should not be over tensioned as this would lead to premature damage on the bearings. The paver's drive chains must be regularly •

checked for sag and retensioned if necessary,

•

checked for wear (e.g. connecting links and tooth flanks etc.),

•

cleaned and lubricated.

When checking the drive chain tension, the connecting links, drag links and sprocket wheels should also be checked for undue wear (damage to the tooth flanks) and renewed if necessary.


4-21

Chapter 4

MAINTENANCE Illustration 16

!

CAUTION

When checking or tensioning the auger drive chains, you should drain the condense water out of the drive case at the same time. A threaded drain plug (10 mm A/F) is located at the lowest position on the auger drive case for draining off any water collected in the case to prevent damage to the auger drive system. Replace and tighten the drain plug (1 & 2) after draining the water.

V-belts

Tension and renew the V-belts according to the instructions in the engine handbook.

4-22


MAINTENANCE

Chapter 4

Drive chains

Illustration 17

•

Push the middle of the chain (2) with a screwdriver to check the tension.

•

The chain must be retensioned if you can depress it by more than 10 mm.

•

To do this, loosen the 4 screws (6) and the locking nut (7).

•

Turn the tensioning screw on the hydro motor clockwise until you can depress the chain by approx. 5 mm. Then tighten the locking nut (7). Remarks: The bearings will wear prematurely if there is too much tension on the drive chain.

•

Now tighten up the 4 screws.

•

Replace the protective cover.


4-23

Chapter 4

MAINTENANCE

Tensioning the conveyors

Illustration 18

Loosen the locking nuts (30 mm A/F), 2 locking per conveyor and tension the conveyor with the 2 nuts (30 mm A/F) located on the front cross member on the paver's frame (1). The conveyor must be equally tensioned so that both sides of the conveyor have the same sag. The sag should measure approx. 50 to 70 mm in a cold condition. After tensioning the conveyor, retighten the locking nuts.

4-24


MAINTENANCE

Chapter 4

Auger Centre Drive

Illustration 19

To check the drive chain tension: •

Remove the cover (1), (4 hex bolts, 13 mm A/F (2)).

•

Rotate the auger shaft to and fro and observe the tension on the drive chain. The drive shaft on the hydraulic motor should not rotate when turning the auger shaft. The tension on the auger drive chain is correct if there is approx. 5 [mm] of free play on the circumference of the auger flight.

To tension the drive chain: •

Loosen the hex nut (24 mm A/F) (3).

•

Loosen the 4 hex bolts (24 mm A/F) (4).

•

Tension the chain with the hex bolt (3) (24 mm A/F) until the above value of approx. 5 mm is reached.

•

Now tighten up the 4 hex bolts.

•

Tighten up the hex nut.

•

Replace the cover.


4-25

Chapter 4

MAINTENANCE

Auger Outer Drives

Illustration 20

To check the drive chain tension: •

Remove the cover (4 bolts 13 mm A/F) (1/2).

•

Press the drive chain with a screwdriver; the chain should only yield slightly, tension the chain if it is too slack. .

To tension the drive chain:

4-26

•

Loosen the 4 bolts (19 mm A/F) and tension the chain with bolt (3/4) (19 mm A/F). .

•

Rotate the auger shaft to and fro and observe the drive chain tension, the drive shaft on the hydraulic motor should not rotate; the tension on the auger drive chain is correct if there is approx. 5 [mm] of free play on the circumference of the auger flight.

•

Tighten up the 4 bolts (19 mm A/F) (3).

•

Replace the cover.


MAINTENANCE

Chapter 4

PRESERVATION FOR LONGER PERIODS OF STANDSTILL Closely observe the measures to be taken described in the engine handbook for longer periods of machine standstill.


4-27

Chapter 4

MAINTENANCE

LUBRICATION PLAN All lubrication instructions contained in this lubrication plan only refer to the basic paver. Lubricating instructions for the paving screed are contained in the operating manual for the screed. Park the paver on level ground before checking the oil levels and changing the oil. Always drain off the oil at operating temperature and catch it in a suitable container. Observe meticulous cleanliness when greasing the machine. Thoroughly clean the grease nipple before applying the grease gun. Slip guides and spindles must be greased or oiled as required especially after cleaning the paver with grease and bitumen dissolving agents. Use a commercially available multi-purpose quality grease. The paver's chain drives must be lubricated once a week. Lubricating work can be done with an oil can or aerosol can. Apply the lubricant between the link plates of the inner and outer links. For normal operating conditions, use a quality brand of oil with a viscosity of SAE oils. Choose an oil to suit your average ambient temperature: Table 21:

Temperature Range

SAE

Viscosity Classification

-5 °C to +25 °C

30

VG 100

+25 °C to +45 °C

40

VG 150

+45 °C to +65 °C

50

VG 220

Once a month clean the chain drives with an oil and grease removing solvent; thereafter oil the chains. At the end of the paving season, thoroughly clean all chains and sprockets and preserve them with a special chain grease. Remarks: After lubricating, remove the grease gun nozzle from the grease nipple by turning the gun clockwise at an angle of approx. 30°. This will make it easier to remove the grease gun without braking off the ball head on the grease nipple. Use extreme CAUTION when working in the vicinity of moving parts. When paving bituminous materials, the conveyor and auger bearings must be immediately lubricated at the end of paving work. To do this, run the conveyors and augers and apply grease until it emerges from the cavities. Any paving material which may have penetrated the seals will be forced out by the lubricant. Grease points with daily intervals must be lubricated before washing the machine so that the gaps in the bearings are closed with grease. Grease points with daily intervals must be lubricated before washing the machine. Do not direct the jet of water onto the bearings.

4-28


MAINTENANCE

Chapter 4

GREASE POINTS The grease points 1 to 5 must be lubricated every 10 operating hours. Lubricant:refer to ”Consumables”, page 7-2 Illustration 22


4-29

Chapter 4

MAINTENANCE Illustration 23

Remarks: Grease points 1 to 5 do not apply to pavers equipped with the central lubrication system. 1: LH & RH auger outer bearings on the basic auger (with centre auger drive); 2 grease nipples 2: Auger centre bearing (with auger centre drive); 3 grease nipples 1a: LH & RH auger outer bearings on the basic auger (with auger outer drives); 2 grease nipples 2a: Auger centre bearing (with auger outer drives); 1 grease nipple 3: LH & RH auger outer bearings on the auger channel (at paving widths beyond 5.50 m); 2 grease nipples 4: Rear LH & RH conveyor drive shaft; 3 grease nipples 5: Front LH & RH conveyor idler; 2 grease nipples

4-30


Chapter 4

MAINTENANCE

The grease points 6 and 7 must be lubricated every 500 operating hours. Lubricant: refer to ”Consumables”, page 7-2 Illustration 24

•

Guide rollers on the LH & RH towing arms; 2 grease nipples

•

Bearing for the LH & RH front track idler, 2 grease nipples.

4-Track Paver Titan 31

225/325

Chapter 4

MAINTENANCE

CENTRAL LUBRICATION SYSTEM (OPTION) At least once a year, the grease lines must be disconnected directly from the users. Activate the central lubrication system and check whether grease emerges from the grease lines. Furthermore, all lubricating channels must be checked for a free passage of grease as illustrated below. Illustration 25

4-32

•

Disconnect the lubricating line (Fig. 1 & 2) and screw in a normal grease nipple (Fig. 3).

•

Apply grease with the grease gun (Fig. 4) until it emerges out of the cavities.

•

Rectify any faults found in the lubrication system.

•

Finally, remove the grease nipple and reconnect the grease line (Fig. 1).


MAINTENANCE

Chapter 4

OIL CHANGE, TRANSMISSION GEARS Illustration 26

Quantity: 2 litres per transmission gear Quality: refer to ”Consumables”, page 7-2 1. Park the paver on level ground and remove the cover plate (1) 2. The oil level plug (1) is positioned horizontally. 3. Unscrew and remove the oil level plug (1). 4. The oil level must reach the lower edge of the hole for the oil level plug (1) (the oil level is then correct). 5. Top up with transmission oil if the oil level is too low. 6. After checking the oil, replace and tighten the oil level plug (1) and the oil filler plug (2). 7. Replace the cover plate (1).


4-33

Chapter 4

MAINTENANCE

OIL CHANGE, PUMP DISTRIBUTOR GEAR Illustration 27

4-34


MAINTENANCE

Chapter 4

Quantity: 1.25 litres Quality: refer to ”Consumables”, page 7-2 Check the oil level: •

Open the engine bonnet

•

Remove the oil dip stick (11a).

•

Use a non-fibrous clean cloth to wipe the dip stick dry and ten return it into the hole in the housing.

•

Remove the dip stick once again and check the oil level.

•

The oil level is correct if it is between the MAX and MIN marks on the dip stick.

•

The oil level is too low if it is just above the MIN mark on the dip stick (the oil level should never be below the MIN mark).

•

Top up or drain off oil to the correct level.

•

Return the dip stick into the hole on the housing.

Draining the Oil: Unscrew and remove the filler plug with dip stick ( 11a) so that air enters the gear and lets the oil trickle out. Then unscrew and remove the drain plug (11c on the LH side of the paver) and catch the oil in a suitable container. Filling the Oil: Fill 1.25 litres of transmission oil MB 90 through the filler plug (11a). Check the oil level with the dip stick as previously described.


4-35

Chapter 4

MAINTENANCE

OIL CHANGE, HYDRAULIC SYSTEM Illustration 28

4-36


MAINTENANCE

Chapter 4

Quantity: 205 litres to fill to complete system; approx. 160 litres for an oil change Quality: refer to ”Consumables”, page 7-2 Table 29:

Temperature Range

SAE

below 0°C

10 W

-10 °C to +15 °C

20W/20

0 °C to +35 °C

30

+25 °C to +50 °C

40

-20 °C to +30 °C

10W/40

Check the oil level: Sight glass on the hydraulic oil tank. Remarks: If the paver has a Variomatic screed, completely retract the screed to check the oil level. Draining the Oil: Drain the oil at operating temperature. Flush the tank to remove any oil sediment (1). Catch the oil in a suitable container. Take the hose from the tool kit and connect it to the drain valve on the bottom of the hydraulic tank. Tighten the threaded connection (12b) until the oil trickles out of the hose. Filling the Oil: Fill oil through the filler neck (12c) on the top of the oil tank. After an oil change, let the Diesel engine run for approx. 5 minutes at idling speed (max. 800 1/min) to let any air escape from the hydraulic lines.


4-37

Chapter 4

MAINTENANCE

OIL CHANGE, DIESEL ENGINE Illustration 30: Engine Oil Drain Hose

Details of maintenance and consumables are contained in the engine handbook. Remarks: The oil consumption may be slightly higher than normal on new engines during the initial running in period of approx. 200 hours. Therefore, check the oil level twice a day during the running in period. If the paver has an operator's cabin, the engine oil will be used for the cab heating system. Before draining the oil, turn the cab heating to the "full ON" position and let the engine run for at least 1 minute with the heating full on. Fill new engine oil with the heating switched to the "ON" position. Thereafter, run the engine for at least 1 minute with the heating switched "ON". Then switch off the engine and check the oil level in the oil sump; top up oil to the MAX mark on the dipstick if necessary. Further instructions for maintenance work and adjustments on the Diesel engine such as cleaning the fuel filter, the fuel feed pump, the tappet clearance and checking the fuel injectors etc can be taken from the appended engine handbook.

4-38


CHAPTER 5 - TROUBLE SHOOTING


5-1

Chapter 5

TROUBLE SHOOTING

TROUBLE SHOOTING

!

WARNING

When trouble shooting, it is absolutely essential that you read and strictly observe the safety instructions contained in Chapter 1 “Safety”, Page 12 of this manual. Improper paver operation and maintenance are the most frequent causes of faults and breakdowns. If a breakdown occurs, first read the operating manual and especially the chapter on maintenance. Notify your service technician or distributor if you cannot locate the cause of the problem or required assistance when replacing faulty parts.

5-2


TROUBLE SHOOTING

Chapter 5

TROUBLE SHOOTING

Fault Engine does not start

Possible Cause

Fault Clearance

Emergency STOP button depressed

Pull up the emergency STOP button and press the ON button (319Page).

Fuse F7 has blown

Check and replace the fuse F7

No set speed value on the speed potentiometer

Check the set value on X1/44 (0-10 V), rectify the wiring fault or replace the potentiometer

Spring loaded brake cannot be released

Check the feed pressure (approx. 30 bar). Check the solenoid Y10, LED illuminates when the brake is released.Check the wiring and rectify the fault.

Machine will only travel in one direction

Short circuit or failure on the proportional solenoids for the travel drive pumps

Check the wiring for short circuits and damage. Check the drive lever (S24). 27Page Check the solenoids on the valves (Y1.1, Y 1.2, Y2.1, Y2.2). Forward travel over a short distance is possible as follows: Swap the cable plugs for forward and reverse travel on the solenoid for the travel drive pump (upper to lower and vice versa). If the problem still occurs, the I/ O module for the travel drive is faulty.

The travel speed cannot be altered

Short circuit or failure on the speed potentiometer

Check the terminal voltage (X1/ 45 = 10 V; X1/44 = 0-10 V).

Machine veers sharply to the left or right

Speed sensors have been interchanged

Swap XE2/13 with XE2/14 in the electronics.

Auxiliary control No function has been allocated to this key

K 29 , K 11 or K 10 faulty or faulty current circuit

Check the fuse F7. Check the relays K29, K10 and K 11 Check the terminal voltage as per the wiring diagram.


5-3

Chapter 5

TROUBLE SHOOTING

Fault Machine does not travel straight ahead

5-4

Possible Cause

Fault Clearance

Control lamp for the speed sensor flashes (faulty sensor or fault in the wiring to the sensor)

Check the cable plugs on the sensor for tight fitting.

Steering potentiometer not adjusted correctly

Check the terminal voltage X1/ 48 and X1/49 (when travelling straight ahead, the voltage must be below 0.1 V).

Diesel engine runs at a too low speed

Check the nominal speed

Short circuit or failure on the steering potentiometer R17/18

Check the terminal voltage X1/ 46 / 51 (10 V). Check the set value X1/48 (0 10 V for LH turn). Check the set value X1/49 (0 10 V for RH turn). Replace the faulty wiring if necessary. Replace the steering potentiometer if necessary.

Faulty solenoids on the travel drive pumps

Check the resistance on the solenoids (both sides should have almost the same value).

Machine cannot be steered

No set value on the steering potentiometer

Check the terminal value (set value) (X1/48 steering left 0 - 10V; X1/49 steering right 0 - 10 V). Rectify the terminal fault or replace the potentiometer.

Speed cannot be switched to transport speed

Failure in the power supply to the solenoids

Check the fuse F9, check the terminal voltage (X1/89 = 24 V; X20.5/3 = 24 V; X20.5/1 and 2 = 12 V). Check solenoid Y3 and Y4, LED illuminates in the transport speed.

"Turning-on-the-spot" does not function

Paver switched to transport speed stage

Switch to paving speed stage (S6).

Faulty switching contact

Check the terminal voltage (faulty switch S77 or power not supplied to X1/57 24 V).


TROUBLE SHOOTING

Chapter 5

Fault

Possible Cause

Fault Clearance

Machine veers to one side when starting

Current on the solenoids for the travel drive pumps is not set correctly.

Offset Adjustment: With the offset adjustment, the starting values are calibrated for the hydraulic pumps on the travel drive system. If a faulty function occurs (e.g. sensor error), the paver will start moving slowly. In this case, the offset adjustment procedure can be immediately stopped by moving the drive lever or pressing the emergency STOP button. For this reason, it is absolutely essential that the operator remains on the operator's platform during the offset procedure (approx. 2 to 3 minutes for each side). Change the electronics to the programming mode (Move the plug-in bridge from X1/115-X1/ 116 to X1/116-X1/117). Start the offset adjustment on the LH side by moving the drive lever forwards. During the calibration, the LH sensor will flash and will permanently illuminate when the calibration is finished. Start the offset adjustment on the RH side by moving the drive lever backwards. During the calibration, the RH sensor will flash and will permanently illuminate when the calibration is finished. Finalise the offset adjustment procedure by moving the plug-in bridge from X1/116-X1/117 back to X1/115-X1/116. Now start the machine moving in the paving speed stage. Repeat the offset adjustment if the machine starts with irregular movements. Contact your nearest service technician if the fault cannot be rectified after several attempts at the offset adjustment procedure.

Only carry out the offset adjustment at operating temperature


5-5

Chapter 5

TROUBLE SHOOTING

Fuses and Relays The fuses and relays are housed in a cabinet on the rear of the control column. Illustration 6:

Table 1: Pos.

Description

Function

1

Fuses

Allocation as per overview (3)

2

Relays

Allocation as per overview (3)

3

Allocation of fuses and relays

NOTICE Replace a blown fuse with a fuse of the same amperage. If the fuse has not blown, the fault may be in that particular circuit. Contact your service technician or distributor if the fuse blows in the same circuit several times without a recognisable cause.

5-6


TROUBLE SHOOTING

Chapter 5

Towing the Paver

!

CAUTION

It is only permitted to tow the paver with a tow bar at a slow towing speed of approx. 10 m/min over a short distance to remove the machine from the danger zone or tow it to a low bed loader. Ensure there are no persons or objects in the danger zone. Observe your locally prevailing laws, regulations and the traffic code when towing the paver. There is a danger of crushing and serious personal injury when preparing the paver for towing. Ensure the crawler tracks do not skid. The paver can only be steered and guided by the towing vehicle if the Diesel engine has broken down. Before unhitching the tow bar, ensure it is not under tension and the paver is secured against moving by applying the spring loaded brake or by wheel chocks. Due to the hydrostatic travel drive, it is not permitted to tow start the Diesel engine if the electric starter has broken down. Any attempt to tow start the Diesel will cause damage to the hydrostatic drive system.


5-7

Chapter 5

TROUBLE SHOOTING

MANUALLY RELEASING THE PARKING BRAKE Illustration 7:

•

(1) = Test connection

•

(2) = Brake valve

•

(3) = Valve unit

•

(4) = Brake connection

•

(5) = Manometer

•

(6) = Brake

1. Connect the manometer to the test connection (1) on the RH drive motor. 2. Remove the brake connection (4) from the brake valve (2). 3. Close the brake valve (2). 4. Screw the brake connection (4) onto the valve unit (3); then close the brake connection. When doing this, the lines must not run dry. 5. Connect the grease gun to the grease nipple on the valve unit (3). 6. Keep pressing the grease gun to pump grease into the line until the manometer (5) shows a pressure of 30 bar. The spring loaded brake (6) is now released. 7. After towing the paver, return the brake system to its original condition.

5-8


TROUBLE SHOOTING

Chapter 5

RELEASING THE HYDRAULIC DRIVE MOTORS TO RUN FREELY Illustration 8:

The oil can flow freely by screwing in the adjusting screws (1) until they are flush with the lock nuts on both tandem mounted drive pumps (2). The oil can then flow freely in the circuit. 1. Loosen the lock nuts on both adjusting screws (1). 2. Screw in the adjusting screws (1) until they are flush with the lock nuts. 3. Retighten the lock nuts. 4. Unscrew the adjusting screws to their original positions and secure them with the lock nut as soon as the paver is ready for operation.


5-9

Chapter 5

TROUBLE SHOOTING

REMOVING PAVING MATERIAL FROM THE AUGER CHANNEL Illustration 9:

The augers can be manually controlled using the two levers (1) if a breakdown or jamming occurs in the hydraulics. Using this manual auger control feature you can remove paving material from the auger channel before towing the paver.

5-10


CHAPTER 6 - TECHNICAL DATA


6-1

Chapter 6

TECHNICAL DATA

Technical Data TITAN 225 GENERAL DATA

Sales and Model Description

Titan 225

Engine

Deutz Diesel BF6M 1013 with turbo charger Titan 225: P=100 kW at 2300 1/m Titan 225EPM: P=112 kW at 2300 1/min

Fuel tank

236 litres

Paving output

Up to 600 t/h, depending on job-site conditions, paving width and paving material

Paving thickness

Up to 300mm

Travel drive

2 electronically controlled hydraulic circuits (each with a variable pump with proportional control and a variable motor with 2-stage adjustment) Auxiliary control via potentiometer

Paving speed

0-16 m/min

Transport speed

0-3.6 km/h

Crawler unit

Crawler tracks with rubber track pads, 9 track rollers, ground contact area approx. 2900 x 305 mm Hinge mounted road scrapers

Hopper

Hopper capacity approx. 13.5 l Hopper locks operated from the platform, hopper wings hydraulically opened and closed

Conveyor system

Paddle type control switches for the conveyors, ultrasonic sensors for the augers, 4 independent hydraulic circuits for the LH & RH conveyors and LH & RH augers Height of conveyor tunnel 373 mm Hordox bolt-on hopper floor plates Augers with hydraulic or mechanical height adjustment (+/-65mm) Augers reversible

6-2


TECHNICAL DATA

Hydraulics

Chapter 6

Power drive: Twin distributor gear mounted on the flywheel side, no pumps on the spur gear side Reduced leakage by using hydraulic hoses Only pressure line filters are used

Electrics

Cable looms used for excellent overview and layout Flexible cable duct used for routing the cables on the platform Battery master switch 4 working lights Option: Generator up to 34 kW

Weight

With VB 78 screed: up to 5.00 m: approx. 16.8 t to 7.50 m: approx. 17.6 t With MB 122 screed: up to 2.50 m: approx. 14.9 t to 7.00 m: approx. 17.0 t

Standard range of supply

Railings with seat console and sun roof, crosssliding control panel, 2 deluxe seats, tool kit and continuous towing arms

Options

Side curtains for sun roof, orange warning beacon, cab with heating, voltage regulator for 12 V levelling system, 2 additional rear working lights, 56 mm spacer blocks for the towing arms, screed anti-climbing lock, screed assist, central lubrication system, emulsion spraying system for cleaning, Pave Control, analogue or digital levelling system, multi-foot levelling beam, levelling tube, spray gun for cleaning, ThermoControl for screed heating, Diesel heating system for Vario screeds


6-3

Chapter 6

TECHNICAL DATA

NOISE AND VIBRATION VALUES

Titan 225 Noise Level The following sound levels were determined according to the provisions of 1.7.4 (f), Annex 1 of the EU Directives for Machinery 98/37/EC: Equivalent continuous A weighted sound power level on the operator's platform: 90 dB(A) Guaranteed maximum A weighted sound power level on the machine: Lw = 110 dB(A) These measurements were made according to ISO 6394, ISO 6396 and ISO 6395 at the nominal speed specified by the manufacturer. The noise values may vary depending on the type of screed fitted to the paver, the paving conditions and the paving material. Therefore, the actual values reached during paving work may deviate from the values specified. Stress on the Operator caused by Vibrations The following values were determined according to the provisions 3.6.3 (a), Annex 1 of the EU Directives for Machinery 98/37/EC: Entire body vibrations on the operator's platform: The weighted effective value of accelerations to which the body is exposed does not exceed 2.5 m/s². The measurements were made according to ISO 5349 and ISO 2631 with the machine operating at the maximum vibration amplitude and maximum frequency.

6-4


TECHNICAL DATA

Chapter 6

DIMENSIONS Illustration 7: Dimensions Titan 225


6-5

Chapter 6

TECHNICAL DATA

TITAN 325 GENERAL DATA

Sales and Model Description

Titan 325

Engine

Deutz Diesel BF6M 1013 with turbo charger P=133 kW at 2300 1/m

Fuel tank

236 litres

Paving output

Up to 700 t/h, depending on job-site conditions, paving width and paving material

Paving thickness

Up to 300mm

Travel drive

2 electronically controlled hydraulic circuits (each with a variable pump with proportional control and a variable motor with 2-stage adjustment) Auxiliary control via potentiometer

Paving speed

0-16 m/min

Transport speed

0-3.6 km/h

Crawler Unit

Crawler tracks with rubber track pads, 9 track rollers, ground contact area approx. 2900 x mm Hinge mounted road scrapers

Hopper

Hopper capacity approx. 13.5 l Hopper locking bolts actuated on the operator's platform Hopper wings hydraulically opened and closed

Conveyor system

4 independent hydraulic circuits for the LH & RH conveyors and LH & RH augers Paddle type control switches for the conveyors, ultrasonic sensors for the augers, Hordox bolt-on hopper floor plates Height of conveyor tunnel 373 mm Augers with hydraulic or mechanical height adjustment (+/-65mm) Augers reversible

6-6


TECHNICAL DATA

Hydraulics

Chapter 6

Power drive: Twin distributor gear mounted on the flywheel side, no pumps on the spur gear side Reduced leakage by using hydraulic hoses Only pressure line filters are used Separate systems for VB resp. VDT-V, MB screeds Separate adaptation for auger length

Electrics

Cable looms used for excellent overview and layout Flexible cable duct used for routing the cables on the platform Battery master switch 4 working lights Option: Generator up to 34 kW

Weight

With VB 78 screed: up to 5.00 m: approx. 17.0 t to 9.00 m: approx. 18.4 t With VB 88 screed: up to 6.00 m: approx. 17.4 t to 9.00 m: approx. 18.6 t With VDT-V78 screed: up to 5.00 m: approx. 17.3 t to 9.00 m: approx. 19.1 t With VDT 121 screed: up to 2.50 m: approx. 15.1 t to 9.00 m: approx. 18.7 t With MB 122 screed: up to 2.50 m: approx. 14.9 t to 10.00 m: approx. 18.1 t

Standard range of supply

Railings with seat console and sun roof, cross sliding control column, 2 deluxe seats, tool kit, continuous towing arms for VB screeds or split towing arms for VDT and MB screeds

Options

Side curtains for sun roof, orange warning beacon, cab with heating, voltage regulator for 12 V levelling system, 2 additional rear working lights, 56 mm spacer blocks for the towing arms, screed anti-climbing lock, screed assist, central lubrication system, emulsion spraying system for cleaning, Pave Control, analogue or digital levelling system, multi-foot levelling beam, levelling tube, spray gun for cleaning, ThermoControl for screed heating, Diesel heating system for Vario screeds


6-7

Chapter 6

TECHNICAL DATA

NOISE AND VIBRATION VALUES

Titan 325 Noise Level The following sound levels were determined according to the provisions of 1.7.4 (f), Annex 1 of the EU Directives for Machinery 98/37/EC: Equivalent continuous A weighted sound power level on the operator's platform: 85 dB(A) Guaranteed maximum A weighted sound power level on the machine: Lw = 106 dB(A) These measurements were made according to ISO 6394, ISO 6396 and ISO 6395 at the nominal speed specified by the manufacturer. The noise values may vary depending on the type of screed fitted to the paver, the paving conditions and the paving material. Therefore, the actual values reached during paving work may deviate from the values specified. Stress on the Operator caused by Vibrations The following values were determined according to the provisions 3.6.3 (a), Annex 1 of the EU Directives for Machinery 98/37/EC: Entire body vibrations on the operator's platform: The weighted effective value of accelerations to which the body is exposed does not exceed 2.5 m/s². The measurements were made according to ISO 5349 and ISO 2631 with the machine operating at the maximum vibration amplitude and maximum frequency.

6-8


TECHNICAL DATA

Chapter 6

DIMENSIONS Illustration 8: Dimensions Titan 325


6-9

Chapter 6

6-10

TECHNICAL DATA


CHAPTER 7 - CONSUMABLES


7-1

Chapter 7

CONSUMABLES

Consumables Lubrication is a major element of preventive maintenance and has a significant effect on the working life of the paver. Regularly lubricating moving parts will reduce the possibility of a breakdown cause by a failure of mechanical components. We recommend the use of genuine lubricants to achieve an optimum working life and performance of the paver. Different lubricants are required to lubricate the paver and its integrated assemblies. This chapter includes a table of assemblies to be lubricated and the lubricant required. If not otherwise specified, the oil levels must be checked as follows: Park the machine on level ground and check the level when the oil is cold. The oil must reach the lower edge of the filling hole on oil check points with a threaded oil level plug. If not otherwise specified, the grease nipples are designed according to SAE-STANDARDS. Lubricate open grease nipples until grease emerges out of the nipple. Applying excessive lubricant to the grease nipple will not damage the grease nipple or its assembly. Insufficient lubricant will, however, shorten the component's working life. If not otherwise specified, lubricate all components without grease nipples (rods, bolts and levers etc.) once a week with oil. A thin film of engine oil will achieve the required lubrication and avoid rust. An anti-seizing solvent can be used if rust or corrosion has formed. Otherwise the component must be cleaned before lubricating. Worn or damaged grease nipples must be replaced if the grease gun cannot be connected or the ball in the nipple has jammed. In addition to the regular lubricating intervals, carry out other inspection and maintenance work at the same time. This will avoid more serious damage occurring on the assemblies. 1. Before starting maintenance work, clean all threaded connections, caps and plugs etc with a non-flammable and non-toxic cleaning solvent so that dirt cannot penetrate the system during work. 2. Drain off all oils at operating temperature. 3. When carrying out lubricating work at the prescribed intervals, check and ensure that all nuts, bolts and screws are correctly tightened. 4. Make a random inspection of threaded connections and nuts and check whether they are tightened to the correct torque. If any loose connections are found, then check and tighten all threaded connections, nuts and bolts. 5. If damage is found during maintenance work, then the machine must be shut down until the faults are rectified. Notify your local distributor if necessary.

7-2


CONSUMABLES

Chapter 7

List of Fuel Oils and Lubricants

WARNING

!

Health and environment hazard when handling hazardous materials Closely observe Chapter 1 “Precautions for Handling Hazardous Goods”, Page 1-8.

Table 1: Description

Application

Quantity

Specification

Diesel engine

20.5 litres

SAE 10W-40ACEA E4-99 / E6-04

Hydraulic oil

hydraulic system

160 litres

HVLP 100, DIN 51524-3

Hydraulic oil

tensioning cylinders

2 x 0.5 litres

HVLP 100, DIN 51524-3

Gear oil

transmission gears

4 litres

SAE 90, ca. 15°E / 50°C

Gear oil

pump distributor gear

1.5 litres

SAE 90, ca. 15°E / 50°C

Grease

vibrator bearings, tampers, auger bearings, conveyor bearings and other grease points

As required

High Temperature Grease

Diesel fuel

Diesel engine (fuel tank)

As required

CEN EN 590 DIN 51601 BS 2869: A1, A2 ASTM D975-88: 1-D, 2-D NATO Code: F-54, F-75

Diesel engine (radiator)

17 litres

Refer to the engine handbook

Engine oil

Engine coolant

NOTICE All quantities are reference values which may vary within a series of machines. After changing or topping up fluids, check the fluid level and correct it if necessary. Contact your nearest distributor or the manufacturer directly if your machine is filled with biodegradable fluids or you wish to change to such fluids.


7-3

Chapter 7

7-4

CONSUMABLES


CHAPTER 8 - TORQUES FOR THREADED CONNECTIONS


8-1

Chapter 8

TORQUES FOR THREADED CONNECTIONS

TORQUES FOR THREADED CONNECTIONS TABLE OF TORQUES - ISO The following table of torques is recommended for nuts and bolts with a metric ISO strength capacity and property class of 8.8 and more. If other torques are required, they will be specified in the text for that particular component. Remarks: The torques apply to galvanized and zinc coated dichromate bolts.

TORQUE Bolt Size

8-2

lbs.-ft.

Nm

M6 x 1.0

9

12

M8 x 1.25

21

28

M10 x 1.5

45

61

M12 x 1.75

79

105

M14 x 2.0

125

170

M16 x 2.0

195

265

M20 x 2.5

380

515

M24 x 3.0

660

895

M30 x 3.5

1310

1780

M36 x 4.0

2290

3100


GLOSSARY OF TERMS


I

Glossary of Terms

Alphabetical Index

D

A

3-61

Daily procedure at the end of paving work . . Additional. . . . . . . . . . . . . . . . . . . . . . . . 2-34 Anti . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Application intended .................................................1-4 unintended use ......................................1-4 At the end of paving work . . . . . . . . . . . 3-61 Auger mode selection . . . . . . . . . 2-12, 2-17 Auger overmodulate . . . . . . . . . . . . . . . 2-21 Auger reverse rotation . . . . . . . . . . . . . 2-13 Auger, operation . . . . . . . . . . . . . 2-12, 2-17

B batteries. . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 charging ...............................................4-14 greasing the terminals .........................4-14 master switch ......................................2-33 battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

C Central . . . . . . . . . . . . . . . . . . . . . 2-24, 4-32 Check the engine oil level . . . . . . . . . . . 4-11 Clean hydraulic oil cooler and radiator ..........4-19 vent filter ..............................................4-18 clean . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Cleaning the Machine . . . . . . . . . . . . . . 4-10 Commissioning the Paver check .....................................................3-6 Consumables . . . . . . . . . . . . . . . . . . . . . 7-2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Control Column, Cross Sliding . . . . . . . 3-16 Control panels external ................................................2-20 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Conveying the mix to one side ...........................................3-59 Conveyors operation ................................... 2-12, 2-17 tensioning ............................................4-24 conveyors . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 Corrosion protection . . . . . . . . . . . . . . . . 1-8 Crawler . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

II

Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Diesel engine Oil change ........................................... 4-38 Dimensions Titan 225 ............................................... 6-5 Titan 325 ............................................... 6-9 direction . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Direction Indicator . . . . . . . . . . . . . . . . . 3-51 Distributor . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Distributor augers Auger height........................................ 3-42 extensions ........................................... 3-46 Filter .................................................... 4-16 Mix flow control ................................... 3-49 with centre drive.................................. 4-25 with outer drives .................................. 4-26 Drive chains . . . . . . . . . . . . . . . . . . . . . . 4-21 Drive lever . . . . . . . . . . . . . . . . . . . . . . . 2-14 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

E Electrical power supply ON / OFF .............................................. 3-7 Electrical system Maintenance ....................................... 4-13 Electrics . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Electronic levelling system . . . . . . . . . . 2-32 Emergency Control . . . . . . . . . . . . . . . . 3-28 Emergency operation . . . . . . . . . 2-38, 3-28 Emergency STOP indicated on the control panel .............. 2-8 release ................................................ 2-10 switch .................................................. 2-10 Emission . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Emulsion . . . . . . . . . . . . . . . . . . . . 2-3, 2-26 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 jump starting ....................................... 3-21 Engine coolant level . . . . . . . . . . . . . . . . 2-8 Engine oil pressure . . . . . . . . . . . . . . . . . 2-8 Engine oil temperature . . . . . . . . . . . . . . 2-7 Engine speed . . . . . . . . . . . . . . . . . . . . . 2-19 Engine, start. . . . . . . . . . . . . . . . . . . . . . 2-14 Important instructions ......................... 3-19 with the starter batteries ..................... 3-20 Engine, stop . . . . . . . . . . . . . . . . . 2-14, 3-23 Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 3-11


Glossary of Terms External . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 External control panels . . . . . . . . . . . . . 2-20

F Feed pressure filter for travel drive and tamper drive . . . . . . . . . . . . . . . . . . . . . 4-17 Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 first aid box compartment ............................... 2-3, 2-22 safekeeping ...........................................0-4 First Oil Change . . . . . . . . . . . . . . . . . . . 4-6 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Front . . . . . . . . . . . . . . . . . . . . . . . 2-3, 3-34 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Tank ............................................. 2-3, 2-23 Fuel filter draining off the condensed water ........4-12 Fuel level indicated on the control panel ...............2-7 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Fuses . . . . . . . . . . . . . . . . . . . 2-35, 2-38, 5-6

Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Hydraulic drive motors, free running . . . . 5-9 Hydraulic oil temperature........................................... 2-8 hydraulic system Oil change ........................................... 4-36 Hydrostatic System . . . . . . . . . . . . . . . . 4-15

I Identification Plate Engine ................................................... 0-4 Machine ................................................ 0-3 ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Ignition switch . . . . . . . . . . . . . . . . . . . . 2-14 Important information general .................................................. 1-3 Important instructions Maintenance ......................................... 4-2 Operation .............................................. 3-3 Instruments . . . . . . . . . . . . . . . . . . . . . . . 2-2

L G gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Gas bottle connection ...........................................2-31 support...................................................2-3 tensioning belt .....................................2-31 Gas heating . . . . . . . . . . . . . . . . . . . . . . 2-30 hose routing .........................................1-11 precautions ..........................................1-10 Precautions for gas leakage ...............1-13 Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 General Data Titan 225 ...............................................6-2 Titan 325 ...............................................6-6 Grease. . . . . . . . . . . . . . . . . . . . . . 1-8, 4-29

H Hazardous goods handling ......................................... 1-8, 4-6 Hazards special ...................................................1-8 Hopper. . . . . . . . . . . . . . . . . . . . . . 2-3, 3-36 Hopper wings . . . . . . . . . . . . . . . . . . . . 2-13 horn . . . . . . . . . . . . . . . . . . . . . . . 2-13, 2-21 hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11


Lashing . . . . . . . . . . . . . . . . . . . . . . . . . 3-66 Lashing the Machine on the Vehicle . . . 3-66 Levelling Cylinders Filter .................................................... 4-16 Levelling System . . . . . . . . . . . . . 2-32, 3-51 Levelling system . . . . . . . . . . . . . . . . . . 2-18 List of Fuel Oils and Lubricants . . . . . . . . 7-3 Live electric cables procedure when touching the cables . 1-14 Loading by crane .............................................. 3-62 on a vehicle with ramps ...................... 3-65 Lubricant list. . . . . . . . . . . . . . . . . . . . . . . 7-3 lubricating . . . . . . . . . . . . . . . . . . . . . . . 3-32 Lubrication . . . . . . . . . . . . . . . . . . . . . . . 4-28

M Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 MAINTENANCE . . . . . . . . . . . . . . . . . . . 4-2 Maintenance before starting ....................................... 4-5 chart ...................................................... 4-7 Electrical system ................................. 4-13 work..................................................... 4-10 maintenance First Oil Change .................................... 4-6

III

Glossary of Terms Manually releasing the parking brake . . . 5-8 Manually removing paving material . . . 5-10 master switch . . . . . . . . . . . . . . . . . . . . 2-33 Mat . . . . . . . . . . . . . . . . . . . . . . . . 2-3, 2-25 Mat thickness adjusting ..............................................3-53 adjustment ................................. 2-20, 2-21 Mat thickness is not correct . . . . . . . . . 3-58 Material . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Mix flow Augers .................................................3-49 Conveyors ...........................................3-50 Moba controller . . . . . . . . . . . . . . . . . . . 2-32

N Noise and Vibration Values Titan 225 ...............................................6-4 Titan 325 ...............................................6-8

O Oil change Diesel engine.......................................4-38 hydraulic system .................................4-36 Pump distributor gear ..........................4-34 transmission gears ..............................4-33 on-the-spot . . . . . . . . . . . . . . . . . . . . . . 3-27 Operating in auxiliary control ...............................3-28 Operating hour meter . . . . . . . . . . . . . . . 2-8 Operating Manual safekeeping ...........................................0-4 Operating Mode Automatic paving ..................................................3-57 setting ..................................................3-52 Operation. . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Important instructions ............................3-3 Operator . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Operator's Platform . . . . . . . . . . . . . . . . . 2-4 extending / retracting...........................3-14 setting up ...............................................3-8 Operator's Seat deluxe .......................................... 2-6, 3-18 Standard ...................................... 2-5, 3-17 ordering . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3

IV

P Panel, control . . . . . . . . . . . . . . . . . . . . . . 2-7 Paver lubricating............................................ 3-32 refuelling ............................................. 3-30 securing .............................................. 3-66 setting up ............................................ 3-29 Towing the paver .................................. 5-7 Paving . . . . . . . . . . . . . . . . . . . . . . 2-3, 3-52 in contaminated areas .......................... 3-4 in the vicinity of overhead electric cables ...

3-4 in the vicinity of railway lines ................ 3-4 in tunnels ............................................... 3-4 mix segregation .................................. 3-58 on bridges ............................................. 3-5 on slopes ............................................... 3-5 Paving mix conveyed too slow .............................. 3-60 to one side .......................................... 3-59 Paving screed extend/retract (Warning light) ............. 2-21 floating mode ...................................... 3-54 operation ....................................2-21, 3-39 screed spacer blocks .......................... 3-42 secure ................................................. 3-36 Tensioning Device .............................. 3-40 transport lock ...................................... 3-36 Personnel responsibilities . . . . . . . . . . . . 1-7 Platform Control panel......................................... 2-7 operator's .............................................. 2-4 Power supply ON / OFF .....................................2-33, 3-7 Preservation. . . . . . . . . . . . . . . . . . . . . . 4-27 Pressure . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Pump distributor gear . . . . . . . . . . . . . . 4-20 Oil change ........................................... 4-34

R Raising and Lowering the Sun Roof . . . . 3-9 Rapid lubrication . . . . . . . . . . . . . . . . . . 2-10 Receiving the machine, procedure . . . . . 0-3 refuelling . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Removing . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Removing paving material from the auger channel . . . . . . . . . . . . . . . . . . . . . . . . . 5-10


Glossary of Terms Responsibilities personnel ...............................................1-7 user / contractor ....................................1-5 Road . . . . . . . . . . . . . . . . . . . . . . . 2-3, 3-35 Rotary sensor . . . . . . . . . . . . . . . . . . . . 2-13

S Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Safety instructions application specific ................................3-4 Safety precautions when gas escapes ..............................1-13 when the machine touches live cables1-14 Schematic . . . . . . . . . . . . . . . . . . . . . . . 1-12 Screed . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 screed . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 Screed / Floating mode . . . . . . . . . . . . . 2-16 Screed anti-climbing lock . . . . . . . . . . . 2-16 Screed assist . . . . . . . . . . . . . . . . . . . . . 2-15 setting the pressure.............................3-60 Screed control . . . . . . . . . . . . . . . . . . . . 2-16 Screed heating . . . . . . . . . . . . . . . . . . . 2-30 Screed raise and lower . . . . . . . . . . . . . 2-17 Screed spacer blocks . . . . . . . . . . . . . . 3-42 Seat Console, Extending and Retracting3-15 Sockets . . . . . . . . . . . 2-35, 2-36, 2-37, 2-40 Speed potentiometer. . . . . . . . . . . . . . . 2-10 Speed stage . . . . . . . . . . . . . . . . . . . . . 2-11 Spring loaded brake indicated on the control panel ...............2-9 Starting . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Steering potentiometer . . . . . . . . . . . . . 2-15 STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 STOP material flow . . . . . . . . . . . . . . . . 2-21 Stopping . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Storage . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Sun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Switch Cabinet operator's platform ..............................2-38 paver's rear wall ..................................2-39

Torques . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Tow point . . . . . . . . . . . . . . . . . . . 2-12, 2-18 Tow point sinks down . . . . . . . . . . . . . . 3-59 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Towing the paver . . . . . . . . . . . . . . . . . . . 5-7 Transmission gear . . . . . . . . . . . . . . . . . 4-20 Transmission gears oil change............................................ 4-33 transport lock . . . . . . . . . . . . . . . . . . . . . 3-36 Trouble . . . . . . . . . . . . . . . . . . . . . . . 5-2, 5-3 Turning . . . . . . . . . . . . . . . . . . . . . 2-11, 3-27

U Unintended Use . . . . . . . . . . . . . . . . . . . . 1-4 User / contractor responsibilities . . . . . . . 1-5 Using the machine for its intended use. . 1-4

V V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Vibrators . . . . . . . . . . . . . . . . . . . . 2-9, 2-27

W Warning beacon . . . . . . . . . . . . . . . . . . 2-34 Warning Horn. . . . . . . . . . . . . . . . 2-13, 2-21 Welding work on the paver Important instructions ........................... 4-6 Windscreen . . . . . . . . . . . . . . . . . . . . . . 3-13 Working . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

X Xenon. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

T Table of torques . . . . . . . . . . . . . . . . . . . 8-2 Tampers . . . . . . . . . . . . . . . . . . . . 2-9, 2-27 Technical Data . . . . . . . . . . . . . . . . . . . . 6-2 Threaded connections . . . . . . . . . . . . . . 8-2 tighten ..................................................4-10 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22


V

Glossary of Terms

VI


The warranty statement is provided within the manual kit shipped with the machine.

Ref. No. VOE21A1004217 CPN 80846710 Printed in Sweden Volvo, Hameln

English CST

ABG 225-325

Recommend Documents