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Transcript of ABG 225-325
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Ref. No. VOE21A1004217
CPN 80846710
Printed in Sweden 2008-05
Volvo, Hameln
English
CST
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California
Proposition 65 WarningDiesel engine exhaust and some of its constituents areknown to the State of California to cause cancer, birth
defects, and other reproductive harm.
California
Proposition 65 WarningBattery posts, terminals and other related accessoriescontain lead and lead compounds, chemicals knownto the State of California to cause cancer and other
reproductive harm.
Wash hands after handling.
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Table of Contents
Track Paver Titan 225/325 1
INTRODUCTION
PROCEDURE WHEN RECEIVING THE MACHINE ..................................................................... 0-3
D ATA REQUIRED FOR ORDERING SPARE PARTS................................................................... 0-3
M ACHINE IDENTIFICATION PLATE ....................................................................................... 0-3
ENGINE IDENTIFICATION PLATE.......................................................................................... 0-4
S AFEKEEPING THE OPERATING M ANUAL AND FIRST AID BOX ............................................. 0-4
SAFETY
EXPLANATION OF THE S AFETY 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 H AZARDS .............................................................................. 1-8
PRECAUTIONS FOR H ANDLING H AZARDOUS GOODS..................................................... 1-8
PRECAUTIONS WHEN H ANDLING G AS HEATING SYSTEMS........................................... 1-10
G AS HOSE ROUTING ......................................................................................... 1-12
S AFETY PRECAUTIONS WHEN GAS ESCAPES .............................................................. 1-13
S AFETY PRECAUTIONS WHEN THE MACHINE TOUCHES LIVE ELECTRIC CABLES ............. 1-14
INSTRUMENTS AND CONTROLS
M ACHINE OVERVIEW ......................................................................................................... 2-3
OPERATOR'S PLATFORM ................................................................................................... 2-4
OPERATOR'S SEAT............................................................................................................ 2-5
STANDARD SEAT ........................................................................................................ 2-5DELUXE SEAT ............................................................................................................ 2-6
CONTROL P ANEL .............................................................................................................. 2-7
EXTERNAL CONTROL P ANELS.......................................................................................... 2-20
STORAGE COMPARTMENTS ............................................................................................. 2-22
FUEL T ANK ..................................................................................................................... 2-23
CENTRAL LUBRICATION SYSTEM (OPTION) ....................................................................... 2-24
M AT THICKNESS SCALES ................................................................................................. 2-25
EMULSION SPRAYING SYSTEM (OPTION).......................................................................... 2-26
POTENTIOMETERS FOR VIBRATORS AND T AMPERS ........................................................... 2-27
SWITCH OFF THE LEVELLING CYLINDERS IN CASE OF BREAKDOWNS ................................. 2-28
SCREED HEATING SYSTEM (OPTION)............................................................................... 2-30
ELECTRONIC LEVELLING SYSTEM (OPTION) ..................................................................... 2-32ELECTRICS ..................................................................................................................... 2-33
B ATTERY M ASTER SWITCH ....................................................................................... 2-33
WORKING LIGHTS ..................................................................................................... 2-34
SOCKETS / FUSES ON THE P AVER'S LH REAR W ALL.................................................. 2-35
SOCKETS ON THE P AVER'S RH REAR W ALL .............................................................. 2-36
SOCKETS ON THE LH AND RH EXTERNAL CONTROL P ANELS ..................................... 2-37
SWITCH C ABINET ON THE OPERATOR'S PLATFORM .................................................... 2-38
SWITCH C ABINET ON THE P AVER'S REAR W ALL......................................................... 2-39
SOCKETS ON THE P AVER'S REAR W ALL .................................................................... 2-40
Ref. No. VOE21A1004217
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Table of Contents
2 Track Paver Titan 225/325
OPERATION
IMPORTANT INSTRUCTIONS FOR OPERATION .......................................................................3-3
APPLICATION SPECIFIC S AFETY INSTRUCTIONS ...................................................................3-4
P AVING IN TUNNELS ....................................................................................................3-4
P AVING IN THE VICINITY OF OVERHEAD ELECTRIC CABLES .............................................3-4
P AVING IN CONTAMINATED AREAS ................................................................................3-4P AVING IN THE VICINITY OF RAILWAY LINES...................................................................3-4
P AVING ON SLOPES .....................................................................................................3-5
P AVING ON BRIDGES....................................................................................................3-5
COMMISSIONING THE P AVER ..............................................................................................3-6
CHECK BEFORE COMMISSIONING THE P AVER ...............................................................3-6
SWITCHING THE POWER SUPPLY ON AND OFF............................................................3-7
SETTING UP THE OPERATOR'S PLATFORM ....................................................................3-8
R AISING AND LOWERING THE SUN ROOF ..............................................................3-9
EXHAUST PIPE, FITTING AND REMOVING .............................................................3-11
FITTING THE SIDE CURTAINS ..............................................................................3-12
WINDSCREEN (OPTION), R AISING 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 B ATTERIES .......................................3-20
JUMP STARTING THE ENGINE .............................................................................3-21
STOPPING THE ENGINE..............................................................................................3-23
STARTING AND STOPPING THE P AVER ..............................................................................3-24
DRIVING THE P AVER 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 ........................................................................................3-28STOPPING THE PAVER ........................................................................................3-28
PREPARING THE P AVER FOR OPERATION..........................................................................3-29
REFUELLING THE P AVER............................................................................................3-30
LUBRICATING THE PAVER ...........................................................................................3-32
FRONT CROSS BEAM ................................................................................................3-34
ROAD SCRAPERS, R AISING AND LOWERING................................................................3-35
LOWERING THE ROAD SCRAPERS .......................................................................3-35
R AISING 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 .......................................................................................3-36R AISING AND SECURING THE SCREED IN THE TRANSPORT LOCK..........................3-38
RELEASING AND LOWERING THE SCREED FROM THE TRANSPORT LOCK ...............3-38
V ARIOMATIC 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 B ASIC AUGERS..................................................3-44
ADJUSTING THE HEIGHT OF THE AUGERS WITH OUTER BEARINGS .......................3-45
FITTING AUGER EXTENSIONS .....................................................................................3-46
AUGER CONTROL, ADJUSTING ...................................................................................3-49
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Track Paver Titan 225/325 3
ADJUSTING THE CONVEYOR CONTROL (P ADDLE 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
P AVING .......................................................................................................................... 3-52
SETTING THE OPERATING MODE AUTOMATIC ............................................................ 3-52M AT THICKNESS, ADJUSTING .................................................................................... 3-53
SCREED FLOATING MODE......................................................................................... 3-54
SCREED HEATING, ON / OFF ................................................................................... 3-56
P AVING IN THE AUTOMATIC MODE............................................................................. 3-57
P AVING MATERIAL PRONE TO SEGREGATION ....................................................... 3-58
M AT THICKNESS IS NOT CORRECT ...................................................................... 3-58
TOW POINT SINKS DOWN DURING PAVING WORK ................................................. 3-59
CONVEYING THE PAVING MIX TO ONE SIDE.......................................................... 3-59
P AVING MATERIAL NOT CONVEYED FAST ENOUGH ............................................... 3-60
SETTING THE PRESSURE ON THE SCREED ASSIST ............................................... 3-60
D AILY PROCEDURE AT THE END OF PAVING WORK ............................................................ 3-61
LOADING AND TRANSPORT .............................................................................................. 3-62
LOADING BY CRANE.................................................................................................. 3-62
LOADING ON A VEHICLE WITH R AMPS ........................................................................ 3-65
L ASHING THE M ACHINE ON THE VEHICLE ................................................................... 3-66
MAINTENANCE
IMPORTANT INSTRUCTIONS ................................................................................................ 4-2
BEFORE STARTING M AINTENANCE WORK .................................................................... 4-5
H ANDLING H AZARDOUS M ATERIALS ............................................................................ 4-6
WELDING WORK ON THE P AVER ................................................................................. 4-6
FIRST OIL CHANGE..................................................................................................... 4-6
M AINTENANCE CHART ....................................................................................................... 4-7M AINTENANCE WORK...................................................................................................... 4-10
M ACHINE (GENERAL) ................................................................................................ 4-10
CLEANING THE M ACHINE ................................................................................... 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 .............. 4-16FEED PRESSURE FILTER FOR THE TRAVEL DRIVE AND T AMPER DRIVE
(ONLY FOR VDT AND VDT-V SCREEDS) ........................................................... 4-17
CLEANING THE VENT FILTER.............................................................................. 4-18
CLEANING THE HYDRAULIC OIL COOLER AND R ADIATOR..................................... 4-19
TRANSMISSION GEARS ............................................................................................. 4-20
CHECK THE PUMP DISTRIBUTOR GEAR ................................................................ 4-20
CHECK THE TRAVEL DRIVE TRANSMISSIONS ........................................................ 4-20
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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.....................................................4-27LUBRICATION 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 P AVER ..........................................................................................................5-7
M ANUALLY RELEASING THE PARKING BRAKE .................................................................5-8
RELEASING THE HYDRAULIC DRIVE MOTORS TO RUN FREELY ......................................5-9
REMOVING P AVING M ATERIAL FROM THE AUGER CHANNEL ........................................5-10
TECHNICAL DATA
TITAN 225.........................................................................................................................6-2
GENERAL D ATA...........................................................................................................6-2
NOISE AND VIBRATION V ALUES....................................................................................6-4
DIMENSIONS ...............................................................................................................6-5TITAN 325.........................................................................................................................6-6
GENERAL D ATA...........................................................................................................6-6
NOISE AND VIBRATION V ALUES....................................................................................6-8
DIMENSIONS ...............................................................................................................6-9
CONSUMABLES
LIST OF FUEL OILS AND LUBRICANTS..................................................................................7-3
TORQUES FOR THREADED CONNECTIONS
T ABLE OF TORQUES - ISO................................................................................................8-2
GLOSSARY OF TERMS
ALPHABETICAL INDEX.........................................................................................................9-II
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INTRODUCTION
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INTRODUCTION
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INTRODUCTION
This operating manual provides the operators and maintenance personnel on the job-site withvital 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 manualbefore 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 waywithout 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.
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INTRODUCTION
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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 theequipment.
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 andefficient 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
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INTRODUCTION
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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 aperfect 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
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CHAPTER1- SAFETY
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SAFETYClosely observe the recommended precautions and instructions for safely operating themachine.
EXPLANATION OF THE SAFETY SYMBOLS
REMARKS: Remarks contain information for the efficient application of the machine.
PLEASE NOTE: Contains general information not connected with danger.
DANGER!
WARNING!
CAUTION!
NOTICE
The safety symbol "DANGER" indicates aspecially dangerous situation. Fatal accidents or
serious injuries will occur if this symbol is notobserved.
The safety symbol "WARNING" indicates apotentially dangerous situation. Fatal accidentsor serious injuries CAN occur if this symbol is notobserved.
The safety symbol "CAUTION" indicates apotentially 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 tospecial assembly, operating or maintenanceinstructions not directly connected with danger.
(Red background)
(Orange background)
(Yellow background)
(Blue background)
Safety symbols used in this manual. Theyindicate a potential danger. Closely observe allsafety symbols to avoid fatal accidents, injuries
and damage to property and the environment.
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Chapter 1 SAFETY
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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 recognizedstandards. Other materials should not be paved with the paver.
The paver may only be operated on a specially prepared surface with sufficient bearingcapacity. 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 onspecial 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 spareparts. 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 theservice 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 isput to unintended use. The manufacturer does not accept any liabilitywhatsoever for personal injury or damage to property if the machine isput to an unintended use.
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SAFETY Chapter 1
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RESPONSIBILITIES OF THE USER / CONTRACTOR
The paver can only operate safely on the job-site if all necessary safety measures have beentaken. It is the responsibility of the user/contractor to plan implement all necessary safetymeasures 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 assignedto 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 aresupervised and controlled by a fully trained and qualified electrician. This work mustbe 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 andauthorized 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 thework in a reliable manner.
• Work on the machine's chassis, the brakes, the hydraulics and the steering systemmay only be carried out by fully qualified personnel who have been appropriatelytrained and have the required skills.
• The personnel must be regularly trained in all matters of occupational health andsafety 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 safetyinstructions 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 operatinginstructions must be supplemented by detailed working instructions appropriate tothe 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 towear protective clothing at all times.All necessary safety precautions must be taken
on the job-site.
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• The contractor / owner must clearly delegate responsibilities to his personnel for
setting up, operating, servicing and repairing the machine. The operator must beauthorised to reject instructions from third persons which may jeopardise safety.
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RESPONSIBILITIES OF THE PERSONNEL
All personnel must ensure the following:
• Thoroughly read the operating manual.You must be able to operate the machinesafely 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 foresightwhen 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 anyquestions 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 allsafety 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 areunder 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 outwithout prior approval by the manufacturer. This applies to the installation andadjustment 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.
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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 properlyhandled (refer to Table1).
Table 1: Precautions for Handling Hazardous Materials
CAUTION!
The following emission will be a health hazard if not properlyhandled (refer to Table2).
Table 2: Precautions for Handling Hazardous Goods
Emission Precaution
Engine exhaustDo not inhale. Avoid an accumulation of
exhaust fumes in closed rooms.
Particles of dust from anelectric motor /
generator (brushes /insulation)
Avoid inhaling dust particles during
maintenance work.
Material Precaution
Anti-freeze solution
(water cooled engine)
Avoid inhaling, swallowing and skin contact;
do not allow to penetrate the environment.
Hydraulic oil Avoid inhaling, swallowing and skin contact;
do not allow to penetrate the environment.
Engine oil Avoid inhaling, swallowing and skin contact;do not allow to penetrate the environment.
Grease Avoid inhaling, swallowing and skin contact;
do not allow to penetrate the environment.
Corrosion protection Avoid inhaling, swallowing and skin contact;
do not allow to penetrate the environment.
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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 nakedflames in the far-reaching surroundings. Donot smoke when refuelling.
Battery water Avoid inhaling, swallowing and skin contact;do not allow to penetrate the environment.
Gear oil Avoid inhaling, swallowing and skin contact;do not allow to penetrate the environment.
Material Precaution
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PRECAUTIONS WHEN HANDLING GAS HEATING SYSTEMS
This chapter contains important instructions for the gas heating system on the paving screedif 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 injuryand 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 andmaintenance of such systems.
• Ensure the complete gas heating system is checked by a fully qualified andauthorized person as follows:
— Before using the gas heating system for the first time, ensure that it is correctlyinstalled and has no gas leaks.
— Check the working safety of the system on completion of all maintenance andrepair 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.
• Your locally prevailing regulations for checking gas bottles still apply and are noteffected by this chapter.
• All gas connections must be checked for leakage and damage.Only use gasdetectors 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 usethe 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 heatingsystem 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.
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• 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 fromthe bottles when they are in an upright position.
• During operation, the gas bottles should not be allowed to become under-cooled asthis may cause an interruption in the flow of gas. Icing on the bottles caused by anexceptionally 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, redhot 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 gasheating 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 ispossible 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 anadequate natural ventilation.
• Fire and explosion precautions must be taken if the heating system is operated inbuildings or areas where explosive gases can be reckoned with. Keep all
combustible objects and cleaning cloths which may ignite away from hot parts on theheating system.
• Parts in the heating system which are subject to wear and deterioration must berenewed 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 notsubject 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.
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Gas Hose Routing
CAUTION!
The hose rupture protector (4) must never be removed or installed inanother position.
Illustration 2
Table 3: Schematic illustration of the propane gas heating system
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
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SAFETY Chapter 1
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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 thevicinity.
• 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 thereis a danger of fire in the area of the heating system, immediately alarm the firebrigade and try to extinguish the fire yourself but do not subject yourself to
danger. Immediately clear the danger zone of all persons.
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SAFETY PRECAUTIONS WHEN THE MACHINE TOUCHES LIVE ELECTRICCABLES
When paving, always keep the machine at an adequate safety distance to overhead electriccables. 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:
• 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 cableis dead.
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CHAPTER 2 - INSTRUMENTS AND
CONTROLS
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INSTRUMENTS AND CONTROLS
WARNING!
In the interest of your own safety and the safety of others, you mustthoroughly read and understand this chapter before operating themachine.
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INSTRUMENTS AND CONTROLS Chapter 2
Track Paver Titan 225/325 2-3
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 indi-cator
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 sys-tem
15 External control panel Operating the screed
16 Emulsion spraying system Cleaning the paver (Option)
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OPERATOR'S PLATFORM
Illustration 2
Table 2:
Pos. Description Function
1 Control panel cover Protects the control panel from rain anddirt
2 Staple for padlock Protection against vandalism
3 Guide tube Cross-sliding the control column
4 Locking bolt hole Secures the control panel against unin-tentional movement
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INSTRUMENTS AND CONTROLS Chapter 2
Track Paver Titan 225/325 2-5
OPERATOR'S SEAT
STANDARD SEAT
CAUTION!
Sudden movements of the seat will cause injuries. Ensure that alladjusting 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
A-B Armrest Armrest raise and lower
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DELUXE SEAT
CAUTION!
Sudden movements of the seat will cause injuries. Ensure that alladjusting levers lock into position after adjusting the seat. Only adjust
the seat when the machine is at a standstill.
Illustration 4:
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
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INSTRUMENTS AND CONTROLS Chapter 2
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CONTROL PANEL
Illustration 5:
Table 5:
Pos. Illustration Description Function
A1 Control lamp,engineoil temperature
Shows the temperature of the en-gine oil. The indicator needle must
be in the green range during oper-ation. If the needle moves into thered range, immediately stop the
engine and eliminate the cause of
overheating (e.g. engine overload-ed, loss of coolant, dirty radiator).
A2 Fuel level indicator Shows the level of fuel in the fueltank.
The exact level can only be shown
when the machine is standing onlevel ground.
A3 No function has been allocated to
this key
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A4 Operating hourmeter
Shows the machine's number ofoperating hours.
A5a Road lights No function has been allocated tothis key
A5b Flashing direction
indicators
No function has been allocated to
this key
A5c Battery charginglamp
Illuminates if the battery is notbeing charged due to a faulty gen-
erator or fault in the electrical sys-tem.
A5d Control lamp engineoil pressure
Illuminates red if the oil pressureis too low (e.g. oil level too low).
Immediately switch off the engine.
An acoustic warning will sound 4minutes after the red lamp illumi-
nates.
A6a Control lamp, enginecoolant level
Illuminates red if the coolant levelis too low. Let the engine run at
idling speed for a few minutes andthen switch it off. An acoustic
warning will sound at the sametime.Caution: Let the engine cool
down before checking the coolantlevel. Also observe the "engine oiltemperature" warning (A1).
A6b Control lamp emer-gency STOP
Illuminates red when the emer-gency STOP button (A11) is
pressed.
A6c Control lamphydraulic oil temper-
ature
Illuminates red if the hydraulic oiltemperature is too high. Immedi-
ately stop the paver. Let the
engine run at a medium speedwith the machine at a standstill to
cool down the hydraulic oil.
Pos. Illustration Description Function
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A6d Control lamp springloaded brake
Illuminates red when the brake isapplied
a) when the paver is switched OFF
b) when the ignition is switchedON but the engine has not been
started
c) when the drive lever (A25) is inthe zero position and the engine is
running.
A7 Toggle switch, vibra-tion
Select the operating mode for thevibration.
Centre Position: Neutral, the vi-
brators are switched OFF.
LH Position (MAN): The vibrators
run permanently (for cleaning pur-poses or adjusting the hydraulics).
RH Position (AUTO): The vibra-tors are switched ON when the
drive lever (A25) is moved to the
forward travel position. The vibra-tors are switched OFF when thedrive lever is returned to the centre
position. This mode is recom-mended for paving work.
A8a Toggle switch,tampers
Select the operating mode for thetampers.
Centre Position: Neutral, thetampers are switched OFF.
LH Position (MAN): The tampers
run permanently (for cleaning pur-poses or adjusting the hydraulics).
RH Position (AUTO): The
tampers are switched ON whenthe drive lever (A25) is moved tothe forward travel position. The
tampers are switched OFF whenthe drive lever is returned to the
centre position. This mode is rec-ommended for paving work.
Pos. Illustration Description Function
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A8b Potentiometer,heavy duty tampers
Potentiometer for setting thetamper frequency.
Potentiometer only with heavy
duty tampers (variable displace-ment pump); refer to 227Page,Pos. 2.
A9 Speed potentiome-
ter
Potentiometer for preselecting the
travelling speed.
The range of travelling speeds de-pends on the position of the speedstage 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 speedrange)
A constantly controlled speed is
only possible at a potentiometersetting of 0:7 m/min and higher.
A10 Control lamp, rapidlubrication
Activate the rapid lubrication atthe end of daily paving work; thecontrol lamp illuminates during the
lubrication process.
A11 Emergency STOPbutton
Released: Normal operation
Depressed: All drives and move-
ments are stopped; the spring
loaded brake is applied.
A12 Release button for
emergency STOPDepressed: Emergency STOP re-
leased.
The emergency STOP button
(A11) must be pulled upwards torelease the emergency stop.
Pos. Illustration Description Function
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A13 Toggle switch,speed stage selector
switch
Switch for selecting the requiredspeed 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 stopwhen changing speed stages on-
the-run. Thereafter, turn the speedpotentiometer to start the paveragain.
A14 Toggle switch, turn-ing on the spot
Used for turning the paver on thespot.
This function can only be activated
when the drive lever (A25) is in thezero position and the and the tog-gle switch (A13) for the speed
stage selection has been moved tothe LH position "L" (paving speed
stage).
LH Position (0): neutral
Move the switch to the RH posi-
tion (I): Turning on-the-spot func-tion is activated.
Rotate the steering potentiometer
(A26) to select the direction forturning on-the-spot. The more you
rotate the steering potentiometer(A26), the faster the paver will
turn.
A15 No function has been allocated to
this key
Pos. Illustration Description Function
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A16 Toggle switch, RHtow point
Toggle switch for altering the pav-ing thickness on the RH side.
The tow point can only be manual-
ly adjusted when the toggle switch(A35) for the levelling system hasbeen moved to the MAN mode.
Centre Position: neutral
Move the switch to the rear (up-wards): Increase the mat thick-
ness
Move the switch to the front(downwards): Reduce the mat
thickness
A17 Toggle switch, RHauger operatingmode
Select the operating mode of theRH auger.
LH Position (MAX): Maximum au-ger speed.In this position the au-
ger will rotate even when theelectronic control fails.
RH Position (PROP): Proportion-al auger speed control according
to material requirements (control-
led by ultrasonic sensors) A18 Toggle switch, RH
Auger ON/OFF con-
trol
RH auger ON / OFF control.
Centre Position: Auger isswitched OFF.
Move the switch to the left(MAX): The auger will rotate in the
mode selected with the toggleswitch A17.
Move the switch to the right(AUTO): The auger will be propor-
tionally controlled by the ultrasonicsensor.
A19 Toggle switch, RHconveyor 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 con-veyor is controlled by the RH pad-
dle type control switch.
Pos. Illustration Description Function
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INSTRUMENTS AND CONTROLS Chapter 2
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A22 Toggle switch, hop-per wings
Hopper wings open and close.
Centre Position: neutral
Move the switch to the rear (up-wards): Close the hopper wings.
Move the switch to the front(downwards): Open the hopper
wings.
Mechanically secure the closedhopper wings with the locking boltswhen transporting the paver.
A21 Toggle switch,
Auger reverse mode
Determine the direction of rotation
on both auger halves.
Centre Position: neutral, the au-ger halves will convey the material
outwards on both sides.
LH Position: Both augers will con-
vey the material to the LH side.
RH Position: Both augers will
convey the material to the RHside.
A22 Button switch, warn-
ing horn
Press the button to sound the
warning horn.Sound the warning horn before
moving the paver to warn otherpersons in the danger zone.
A23 Control lamp, rotary
sensor
Flashes if the rotary sensor or its
wiring fails on the RH or LH trans-mission gear.
Pos. Illustration Description Function
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Chapter 2 INSTRUMENTS AND CONTROLS
2-14 Track Paver Titan 225/325
A24 Ignition switch Starting and stopping the engine
From left to right:
Position „P“: Parking position(P), the ignition key can be re-
moved
Position „0“: Engine cut-out (be-fore stopping the engine, let it run
for approx. 5 minutes without loadat a higher speed to cool down).
Position „1“: Switch on the igni-
tion; the control lamps will illumi-nate
Position „2“: Start the engine
To start the engine, the drive lever
(A25) must be in the neutral posi-
tion.
A25 Drive lever For driving the paver forward orbackward up to the speed set on
the speed potentiometer (A9).
Release the drive lever by placing
two fingers underneath and eitherside of the knob and lifting it gen-
tly.
Centre Position: neutral, thepave is at a standstill and the
spring brake is applied.
Gently move the drive lever for-wards as far as it will go: Thepaver travels forwards
Gently move the drive lever
backwards as far as it will go: The paver travels backwards
All automatic functions (except theconveyors) can only be activated
when the paver is travelling for-wards.
Pos. Illustration Description Function
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A26 Steering potentiom-eter
For steering the paver
Centre Position: The paver trav-els straight ahead.
Rotate to the left: The paver willtravel 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 thescreed sinking downwards duringpaving work and improves the
paver's traction.
If required, a variable pressure be-tween 10 and 50 bar can be ap-
plied to the screed transportcylinders.
This pressure counteracts theweight of the screed and prevents
it sinking into paving material with
a low bearing capacity. This optiondoes not effect the screed's float-ing behaviour; the screed will bear
down on the material with a re-duced load.
LH Position (ON): Screed assist
is switched ON
RH Position(OFF): The screed
assist is switched OFF
Pos. Illustration Description Function
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Chapter 2 INSTRUMENTS AND CONTROLS
2-16 Track Paver Titan 225/325
A28 Toggle switch,screed anti-climbing
lock (Option)
Screed anti-climbing lock ON /OFF.
If required, the screed transport
cylinders can be hydraulicallylocked in position to prevent thescreed from raising.
The anti-climbing lock prevents
the screed from climbing up andover paving material which hascooled 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 levermoved to the forward travel posi-
tion and the screed switched to thefloating mode.
LH Position (ON): The screedanti-climbing lock will be switched
on for approx. 10 seconds whenthe 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 canbe manually raised and lowered
using the toggle switch (A31).
RH Position (1): Screed floatingmode
Only switch on the floating mode
after the screed has been lowered
e.g. resting on squared timbers
Ensure no persons are in the dan-ger zone when raising or loweringthe screed or during transport.
A30 Control lamp,screed
floating mode
Illuminates when the screed has
been switched to the floating mode(toggle switch A29 moved to posi-
tion 1).
Pos. Illustration Description Function
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INSTRUMENTS AND CONTROLS Chapter 2
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A31 Toggle switch,Screed raise / lower
Screed raise and lower
Move the switch to therear:Screed raise
Move the switch to the front(downwards): Screed lower
A32 Toggle switch, LHauger operatingmode
Select the operating mode of theLH auger.
LH Position (MAX): Maximum au-ger speed.
RH Position (PROP): Proportion-al auger speed control according
to material requirements.
A33 Toggle switch, LH Auger ON/OFF con-
trol
LH auger ON / OFF control.
Centre Position: Auger isswitched OFF.
Move the switch to the left
(MAX): The auger will rotate in themode selected with the toggle
switch A32.
Move the switch to the right(AUTO): The auger will be propor-
tionally controlled by the ultrasonicsensor.
A34 Toggle switch, LHconveyor operating
mode
LH conveyor ON / OFF.
Centre Position: Conveyor isswitched OFF.
LH Position (MAN): Conveyor ismanually switched ON and OFF.
RH Position (AUTO): The con-
veyor is controlled by the LH pad-dle type control switch.
Pos. Illustration Description Function
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A35 Toggle switch, Lev-elling system
Levelling system control.
Centre Position: The levelling
system is switched OFF.
LH Position (MAN): The levelling
system will function when the ma-
chine is paving and at a machinestandstill. This permits the mat
thickness to be corrected using thetoggle switches (A16) for the RHtow point and (A37) for the LH tow
point. We recommend to use this
position only for setting up the lev-elling system at the start of pavingwork.
RH Position (AUTO): The level-
ling system will control the matthickness during paving work.This
position is recommended for pav-ing.
A36 No function has been allocated to
this key
A37 Toggle switch,LH
tow point
Toggle switch for altering the pav-
ing thickness on the LH side.
The tow point can only be manual-ly adjusted when the toggle switch
(A35) for the levelling system hasbeen moved to the MAN mode.
Move the switch to the rear (up-
wards): Increase the mat thick-ness
Centre Position: neutral
Move the switch to the front(downwards): Reduce the mat
thickness
Pos. Illustration Description Function
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A38 Lever, engine speedcontrol
Throttle lever for engine speed.
Move the lever upwards: In-crease the engine speed
Move the lever downwards: Re-duce the engine speed
Pos. Illustration Description Function
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Chapter 2 INSTRUMENTS AND CONTROLS
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EXTERNAL CONTROL PANELS
The external control panels are mounted mirror inverted at the rear of the paver on the LH andRH sides.
Illustration 6:
Table 6:
Pos. Illustration Description Function
B1 Button switch,Increase mat thick-
ness
Increase the angle of attack on theLH and RH side of the screed to in-
crease the mat thickness.
Ensure the tow points are not ad-
justed to opposite limit stops (one
tow point to the upper and one towpoint to the lower limit stop). Thiswill cause undue torsion and twist-
ing on the screed. The maximumpermissible difference in height
between the LH & RH mat thick-ness scales must not exceed 100mm.
Never operate the tow point ad-
justment when the screed is raised
and secured in the transport locksotherwise damage will occur to the
locking device.
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INSTRUMENTS AND CONTROLS Chapter 2
Track Paver Titan 225/325 2-21
B2 Button switch,Reduce the mat
thickness
Reduce the angle of attack on theLH and RH side of the screed to
reduce the mat thickness. Refer to
B1.
B3 Button switch,over-
modulating the
augers
For overmodulating the RH re-
spectively the LH auger.
Use the overmodulating function ifyou require a higher head of mate-
rial in the auger channel for a shorttime (e.g. just before extending the
Vario screed).
The respective auger will rotate atmaximum speed as long as you
keep the button switch depressed.Condition: Pressure switch B7 ispulled upwards.
B4 Button switch,Vario
screed extend
Extend the LH / RH Vario
screed.The warning light B8 will
flash when the Vario screed isextended.
B5 Button switch, Varioscreed retract
Retract the LH / RH Vario screed.The warning light B8 will flash
when the Vario screed is
extended.
B6 Button switch, warn-ing horn
Press the button to sound thewarning horn.
B7 Pressure switchSTOP material flow
The material flow (conveyors andaugers) can be stopped separately
on both sides if the head of materi-al in the auger channel is too high.
Released: Normal operation
Depressed: LH respectively RHconveyor and auger will be
stopped.
B8 Warning light Varioscreed extend /
retract
Flashes when the Vario screed isextended or retracted.
Pos. Illustration Description Function
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Chapter 2 INSTRUMENTS AND CONTROLS
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STORAGE COMPARTMENTS
Illustration 7:
Table 7:
Pos. Description Location
1 Tool box tray Underneath the deck plate on the oper-ator's platform
2 Compartment for First aid box andoperating manual RH side on the operator's platform
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INSTRUMENTS AND CONTROLS Chapter 2
Track Paver Titan 225/325 2-23
FUEL TANK
Illustration 8:
Table 8:
Pos. Description Function
1 Filler cap Topping up with Diesel fuel; new pavers
are supplied with the ignition key for theignition switch (A24) fastened on theinside of the filler cap
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Chapter 2 INSTRUMENTS AND CONTROLS
2-24 Track Paver Titan 225/325
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. Description Function
1 Central lubrication system Lubricates the basic auger, conveyordrive 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 lubri-
cant
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Track Paver Titan 225/325 2-25
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 thicknessare included in the operating manual for your paving screed.
Illustration 10:
Table 10:
Pos. Description Function
1 Mat thickness scales Indicates the approx. paving thickness
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Chapter 2 INSTRUMENTS AND CONTROLS
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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 allowthe cleaning solvent to seep into the ground.
Fire hazard Do not use flammable cleaning solvents. Only start sprayingthe cleaning solvent after the burner chambers have cooled down
(approx. 10 minutes after switching off the heating system).
Illustration 11:
Table 11:
Pos. Description Function
1 Stop valve Hose connection with ball cock2 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 cleaningsolvent
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INSTRUMENTS AND CONTROLS Chapter 2
Track Paver Titan 225/325 2-27
POTENTIOMETERS FOR VIBRATORS AND TAMPERS
Illustration 12:
Table 12:
Pos. Description Function
1 Potentiometer, vibrators Setting the vibrators
Rotate clockwise: reduce the vibrator
speed
Rotate anti-clockwise: increase the vi-brator speed
2 Potentiometer, Tampers“ (This potenti-
ometer is installed with the standardtampers without variable displacement
pump). The potentiometer for the heavyduty tampers is located on the control
panel -refer to 210Page, Pos. A8b)
Setting the tampers
Rotate clockwise: reduce the tamperspeed
Rotate anti-clockwise: increase the
tamper speed
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Chapter 2 INSTRUMENTS AND CONTROLS
2-28 Track Paver Titan 225/325
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 thepaver, the screed will be subject to excess torsion and will be damaged.
Illustration 13:
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INSTRUMENTS AND CONTROLS Chapter 2
Track Paver Titan 225/325 2-29
Table 13:
Pos. Description Function
1 Ball cock, levelling cylinder Switch off the hydraulic circuit for the RH
or LH levelling cylinder n case of abreakdown (Location:on the RH and LHlevelling cylinders).
Lever position vertical (as illustrat-ed): Normal position, the ball cock is
open, the hydraulic is switched on and
the levelling cylinder is ready for opera-tion
Lever position horizontal: The ballcock is closed, the hydraulic circuit is
blocked; the levelling cylinder is
switched off. Levelling is not possible.
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Chapter 2 INSTRUMENTS AND CONTROLS
2-30 Track Paver Titan 225/325
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 par-
ticular screed are included in the screed's operating manual. There is a separate operatingmanual for the temperature controlled gas blower heating system (Thermo-Control).
Strictly observe all locally prevailing directives and laws for operating the heating system onyour 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 theoperating manual for your particular paving screed.
The heating gas used should, if possible, be pure propane gas and at ambient temperaturesabove 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 gasbottles 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 raysleading 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.
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INSTRUMENTS AND CONTROLS Chapter 2
Track Paver Titan 225/325 2-31
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 standardgas 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
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Chapter 2 INSTRUMENTS AND CONTROLS
2-32 Track Paver Titan 225/325
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 tensionedlevelling wire).
We do not recommend using a levelling system for paving a wearing course if the previousbinder course is smooth and level.
Further information on the application of the optional levelling system is included in a separateinstruction manual.
Illustration 15
Table 15:
Pos. Description Function
1 Support, Moba controller For installing the optional Moba control-
ler
2 Assembly plate Electronic levelling sys-tem
Assembly plate for the optional elec-tronic levelling system
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INSTRUMENTS AND CONTROLS Chapter 2
Track Paver Titan 225/325 2-33
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. Description Function
1 Battery Master Switch Switch off the power supply at the end of
work
Vertical position: Power supplyswitched on (illustration refers)
Horizontal position: Power supply isswitched off (as an additional anti-theft
measure, remove the plastic key fromthe master switch in this position at the
end of work).
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Chapter 2 INSTRUMENTS AND CONTROLS
2-34 Track Paver Titan 225/325
WORKING LIGHTS
Illustration 17:
Table 17:
Pos. Description Function
1 Working lights Illuminating the front and rear workingarea 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 workingarea;ON / OFF switch located on the
roof strut
4 Additional Working Lights (Option) For illuminating the auger channel
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INSTRUMENTS AND CONTROLS Chapter 2
Track Paver Titan 225/325 2-35
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 addi-
tional working lights
3 24-V socket Socket for the working lights or addi-tional working lights
4 Fuse box Fuses F83 to F90 (refer to the allocation
of fuses in the switch cabinet on thecontrol column)
5 24-V socket Socket for the gas burners on the Vario-
matic screed - basic width
6 24-V socket Socket for the control cable; the socketmust be connected during paving work
otherwise the LH auger will not function
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Chapter 2 INSTRUMENTS AND CONTROLS
2-36 Track Paver Titan 225/325
SOCKETS ON THE PAVER'S RH REAR WALL
Remarks: Ensure the sockets are closed with the protective caps whennot in use. This will avoid moisture and dirt damaging the sockets.
Illustration 19:
Table 19:
Pos. Function FUNCTION
1 24-V socket Socket for the levelling system / LHslope controller
2 24-V socket Socket for the working lights or addi-tional working lights
3 24-V socket Socket for the working lights or addi-tional working lights
4 24-V socket Socket for the control cable; the socketmust be connected during paving work
otherwise the LH auger will not function
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INSTRUMENTS AND CONTROLS Chapter 2
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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 Socket for the control cable; the socket
must be connected during paving workotherwise the LH auger will not function
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
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Chapter 2 INSTRUMENTS AND CONTROLS
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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. 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 emer-gency control if a fault occurs in the
electronics
Top position: Emergency operationLower position: Normal operation
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INSTRUMENTS AND CONTROLS Chapter 2
Track Paver Titan 225/325 2-39
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 dirtdamaging 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 forfunctions.
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Chapter 2 INSTRUMENTS AND CONTROLS
2-40 Track Paver Titan 225/325
SOCKETS ON THE PAVER'S REAR WALL
Remarks: Ensure the sockets are closed with the protective caps whennot in use. This will avoid moisture and dirt damaging the sockets.
Illustration 23:
Table 23:
Pos. Description Function
1 Connection, hydraulic crown control Refer to the documentation for thescreed
2 Socket Not relevant for operation
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Track Paver Titan 225/325 3-1
CHAPTER 3 - OPERATION
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Chapter 3 OPERATION
3-2 Track Paver Titan 225/325
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. Thereduction of engine output may only be carried out by the enginemanufacturer.
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OPERATION Chapter 3
Track Paver Titan 225/325 3-3
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 thesesources 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 handsignals to be used.
• The operator must not leave the operator's platform when the engine is running. Donot 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 pavingwidth 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 unintentionalmovement and unauthorised access. Remove the ignition key.
• Park the machine on firm ground with sufficient bearing capacity.
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Chapter 3 OPERATION
3-4 Track Paver Titan 225/325
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 d