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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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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4 Track Paver Titan 225/325

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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Track Paver Titan 225/325 0-1

INTRODUCTION

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INTRODUCTION

0-2 Track Paver Titan 225/325

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


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


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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Chapter 1 SAFETY


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


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


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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Chapter 1 SAFETY


• 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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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 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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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 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;


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

Grease Avoid inhaling, swallowing and skin contact;


Corrosion protection Avoid inhaling, swallowing and skin contact;


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SAFETY Chapter 1


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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Chapter 1 SAFETY


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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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 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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Chapter 1 SAFETY


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


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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Chapter 1 SAFETY


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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Chapter 2 INSTRUMENTS AND CONTROLS


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


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:


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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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:


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:


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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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.


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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.


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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.


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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.


this key


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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.


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A22 Toggle switch, hop-per wings

Hopper wings open and close.


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.


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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.


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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


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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).


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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.


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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.


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


Move the switch to the front(downwards): Reduce the mat

thickness


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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


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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:


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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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.


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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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FUEL TANK

Illustration 8:

Table 8:


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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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:


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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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:


1 Mat thickness scales Indicates the approx. paving thickness

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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:


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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POTENTIOMETERS FOR VIBRATORS AND TAMPERS

Illustration 12:

Table 12:


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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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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Table 13:


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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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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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:


1 Gas bottle connection Gas hose with pressure reducer

2 Gas bottle tensioning belt Securing the bottle against falling over

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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:


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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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:


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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WORKING LIGHTS

Illustration 17:

Table 17:


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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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:


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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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



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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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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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:


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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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:


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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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:


1 Connection, hydraulic crown control Refer to the documentation for thescreed

2 Socket Not relevant for operation

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CHAPTER 3 - OPERATION

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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. Thereduction of engine output may only be carried out by the enginemanufacturer.

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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 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


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

ABG 225-325

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Transcript of ABG 225-325