Professional Documents
Culture Documents
VOE21A1004217
CPN 80846710
Printed in Sweden 2008-05
Volvo, Hameln
English
CST
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
California
Proposition 65 Warning
Battery posts, terminals and other related accessories
contain lead and lead compounds, chemicals known
to the State of California to cause cancer and other
reproductive harm.
Wash hands after handling.
Table of Contents
INTRODUCTION
PROCEDURE WHEN RECEIVING THE MACHINE ..................................................................... 0-3
DATA REQUIRED FOR ORDERING SPARE PARTS................................................................... 0-3
MACHINE IDENTIFICATION PLATE ....................................................................................... 0-3
ENGINE IDENTIFICATION PLATE .......................................................................................... 0-4
SAFEKEEPING THE OPERATING MANUAL AND FIRST AID BOX ............................................. 0-4
SAFETY
EXPLANATION OF THE SAFETY SYMBOLS ........................................................................... 1-2
IMPORTANT GENERAL INFORMATION .................................................................................. 1-3
INTENDED AND UNINTENDED USE ...................................................................................... 1-4
INTENDED USE ........................................................................................................... 1-4
UNINTENDED USE....................................................................................................... 1-4
RESPONSIBILITIES OF THE USER / CONTRACTOR ................................................................. 1-5
RESPONSIBILITIES OF THE PERSONNEL .............................................................................. 1-7
INSTRUCTIONS FOR SPECIAL HAZARDS .............................................................................. 1-8
PRECAUTIONS FOR HANDLING HAZARDOUS GOODS ..................................................... 1-8
PRECAUTIONS WHEN HANDLING GAS HEATING SYSTEMS ........................................... 1-10
GAS HOSE ROUTING ......................................................................................... 1-12
SAFETY PRECAUTIONS WHEN GAS ESCAPES .............................................................. 1-13
SAFETY PRECAUTIONS WHEN THE MACHINE TOUCHES LIVE ELECTRIC CABLES ............. 1-14
Table of Contents
OPERATION
IMPORTANT INSTRUCTIONS FOR OPERATION .......................................................................3-3
APPLICATION SPECIFIC SAFETY INSTRUCTIONS ...................................................................3-4
PAVING IN TUNNELS ....................................................................................................3-4
PAVING IN THE VICINITY OF OVERHEAD ELECTRIC CABLES .............................................3-4
PAVING IN CONTAMINATED AREAS ................................................................................3-4
PAVING IN THE VICINITY OF RAILWAY LINES ...................................................................3-4
PAVING ON SLOPES .....................................................................................................3-5
PAVING ON BRIDGES....................................................................................................3-5
COMMISSIONING THE PAVER ..............................................................................................3-6
CHECK BEFORE COMMISSIONING THE PAVER ...............................................................3-6
SWITCHING THE POWER SUPPLY ON AND OFF............................................................3-7
SETTING UP THE OPERATOR'S PLATFORM ....................................................................3-8
RAISING AND LOWERING THE SUN ROOF ..............................................................3-9
EXHAUST PIPE, FITTING AND REMOVING .............................................................3-11
FITTING THE SIDE CURTAINS ..............................................................................3-12
WINDSCREEN (OPTION), RAISING AND LOWERING ...............................................3-13
OPERATOR'S PLATFORM, EXTENDING AND RETRACTING ......................................3-14
SEAT CONSOLE, EXTENDING AND RETRACTING ...................................................3-15
CONTROL COLUMN, CROSS SLIDING ...................................................................3-16
OPERATOR'S SEAT, ADJUSTING (STANDARD SEAT) .............................................3-17
OPERATOR'S SEAT, ADJUSTING (DELUXE SEAT) .................................................3-18
STARTING THE ENGINE ..............................................................................................3-19
STARTING THE ENGINE WITH THE STARTER BATTERIES .......................................3-20
JUMP STARTING THE ENGINE .............................................................................3-21
STOPPING THE ENGINE..............................................................................................3-23
STARTING AND STOPPING THE PAVER ..............................................................................3-24
DRIVING THE PAVER ON ROADS AND JOB-SITES .........................................................3-25
TURNING ON-THE-SPOT) ............................................................................................3-27
OPERATING THE PAVER IN AUXILIARY CONTROL (EMERGENCY CONTROL) ...................3-28
STARTING THE PAVER ........................................................................................3-28
STOPPING THE PAVER ........................................................................................3-28
PREPARING THE PAVER FOR OPERATION ..........................................................................3-29
REFUELLING THE PAVER............................................................................................3-30
LUBRICATING THE PAVER ...........................................................................................3-32
FRONT CROSS BEAM ................................................................................................3-34
ROAD SCRAPERS, RAISING AND LOWERING................................................................3-35
LOWERING THE ROAD SCRAPERS .......................................................................3-35
RAISING THE ROAD SCRAPERS ...........................................................................3-35
ADJUSTING THE ROAD SCRAPERS ......................................................................3-35
HOPPER WINGS, OPEN AND CLOSE ...........................................................................3-36
HOPPER WINGS, OPEN AND CLOSE ....................................................................3-36
SCREED TRANSPORT LOCK .......................................................................................3-36
RAISING AND SECURING THE SCREED IN THE TRANSPORT LOCK..........................3-38
RELEASING AND LOWERING THE SCREED FROM THE TRANSPORT LOCK ...............3-38
VARIOMATIC SCREED, EXTEND AND RETRACT ............................................................3-39
SCREED TENSIONING DEVICE, ASSEMBLING AND DISMANTLING ...................................3-40
SCREED SPACER BLOCKS (OPTION) ..........................................................................3-42
FITTING THE SCREED SPACER BLOCKS ...............................................................3-42
REMOVING THE SCREED SPACER BLOCKS ..........................................................3-42
AUGER HEIGHT ADJUSTMENT ....................................................................................3-42
ADJUSTING THE HEIGHT OF THE BASIC AUGERS..................................................3-44
ADJUSTING THE HEIGHT OF THE AUGERS WITH OUTER BEARINGS .......................3-45
FITTING AUGER EXTENSIONS .....................................................................................3-46
AUGER CONTROL, ADJUSTING ...................................................................................3-49
Table of Contents
ADJUSTING THE CONVEYOR CONTROL (PADDLE TYPE CONTROL SWITCHES) ............... 3-50
TOO MUCH MATERIAL IN THE AUGER CHANNEL .................................................... 3-50
NOT ENOUGH MATERIAL IN THE AUGER CHANNEL ................................................ 3-50
DIRECTION INDICATOR, SETTING UP .......................................................................... 3-51
ELECTRONIC LEVELLING SYSTEM .............................................................................. 3-51
PAVING .......................................................................................................................... 3-52
SETTING THE OPERATING MODE AUTOMATIC ............................................................ 3-52
MAT THICKNESS, ADJUSTING .................................................................................... 3-53
SCREED FLOATING MODE ......................................................................................... 3-54
SCREED HEATING, ON / OFF ................................................................................... 3-56
PAVING IN THE AUTOMATIC MODE ............................................................................. 3-57
PAVING MATERIAL PRONE TO SEGREGATION ....................................................... 3-58
MAT THICKNESS IS NOT CORRECT ...................................................................... 3-58
TOW POINT SINKS DOWN DURING PAVING WORK ................................................. 3-59
CONVEYING THE PAVING MIX TO ONE SIDE .......................................................... 3-59
PAVING MATERIAL NOT CONVEYED FAST ENOUGH ............................................... 3-60
SETTING THE PRESSURE ON THE SCREED ASSIST ............................................... 3-60
DAILY PROCEDURE AT THE END OF PAVING WORK ............................................................ 3-61
LOADING AND TRANSPORT .............................................................................................. 3-62
LOADING BY CRANE.................................................................................................. 3-62
LOADING ON A VEHICLE WITH RAMPS ........................................................................ 3-65
LASHING THE MACHINE ON THE VEHICLE ................................................................... 3-66
MAINTENANCE
IMPORTANT INSTRUCTIONS ................................................................................................ 4-2
BEFORE STARTING MAINTENANCE WORK .................................................................... 4-5
HANDLING HAZARDOUS MATERIALS ............................................................................ 4-6
WELDING WORK ON THE PAVER ................................................................................. 4-6
FIRST OIL CHANGE..................................................................................................... 4-6
MAINTENANCE CHART ....................................................................................................... 4-7
MAINTENANCE WORK ...................................................................................................... 4-10
MACHINE (GENERAL) ................................................................................................ 4-10
CLEANING THE MACHINE ................................................................................... 4-10
TIGHTEN THREADED CONNECTIONS .................................................................... 4-10
DIESEL ENGINE ........................................................................................................ 4-11
CHECK THE ENGINE OIL LEVEL ........................................................................... 4-11
FUEL FILTER - DRAINING OFF THE WATER ........................................................... 4-12
ELECTRICAL SYSTEM ................................................................................................ 4-13
CHARGE THE BATTERY ...................................................................................... 4-14
GREASING THE BATTERY TERMINALS .................................................................. 4-14
HYDROSTATIC SYSTEM ............................................................................................. 4-15
HIGH PRESSURE FILTER FOR THE LEVELLING CYLINDERS AND AUGERS .............. 4-16
FEED PRESSURE FILTER FOR THE TRAVEL DRIVE AND TAMPER DRIVE
(ONLY FOR VDT AND VDT-V SCREEDS) ........................................................... 4-17
CLEANING THE VENT FILTER .............................................................................. 4-18
CLEANING THE HYDRAULIC OIL COOLER AND RADIATOR ..................................... 4-19
TRANSMISSION GEARS ............................................................................................. 4-20
CHECK THE PUMP DISTRIBUTOR GEAR ................................................................ 4-20
CHECK THE TRAVEL DRIVE TRANSMISSIONS ........................................................ 4-20
Table of Contents
DRIVE CHAINS AND V-BELTS ......................................................................................4-21
V-BELTS ............................................................................................................4-22
DRIVE CHAINS ....................................................................................................4-23
TENSIONING THE CONVEYORS ............................................................................4-24
AUGER CENTRE DRIVE.......................................................................................4-25
AUGER OUTER DRIVES ......................................................................................4-26
PRESERVATION FOR LONGER PERIODS OF STANDSTILL .....................................................4-27
LUBRICATION PLAN ..........................................................................................................4-28
GREASE POINTS .......................................................................................................4-29
CENTRAL LUBRICATION SYSTEM (OPTION) .................................................................4-32
OIL CHANGE, TRANSMISSION GEARS .........................................................................4-33
OIL CHANGE, PUMP DISTRIBUTOR GEAR....................................................................4-34
OIL CHANGE, HYDRAULIC SYSTEM .............................................................................4-36
OIL CHANGE, DIESEL ENGINE ....................................................................................4-38
TROUBLE SHOOTING
TROUBLE SHOOTING ...................................................................................................5-3
FUSES AND RELAYS ...........................................................................................................5-6
TOWING THE PAVER ..........................................................................................................5-7
MANUALLY RELEASING THE PARKING BRAKE .................................................................5-8
RELEASING THE HYDRAULIC DRIVE MOTORS TO RUN FREELY ......................................5-9
REMOVING PAVING MATERIAL FROM THE AUGER CHANNEL ........................................5-10
TECHNICAL DATA
TITAN 225 .........................................................................................................................6-2
GENERAL DATA ...........................................................................................................6-2
NOISE AND VIBRATION VALUES ....................................................................................6-4
DIMENSIONS ...............................................................................................................6-5
TITAN 325 .........................................................................................................................6-6
GENERAL DATA ...........................................................................................................6-6
NOISE AND VIBRATION VALUES ....................................................................................6-8
DIMENSIONS ...............................................................................................................6-9
CONSUMABLES
LIST OF FUEL OILS AND LUBRICANTS..................................................................................7-3
GLOSSARY OF TERMS
ALPHABETICAL INDEX .........................................................................................................9-II
INTRODUCTION
0-1
INTRODUCTION
INTRODUCTION
This operating manual provides the operators and maintenance personnel on the job-site with
vital instructions, rules and criteria for operating and servicing the track paver model Titan 225/
325.
The operator must carefully read and understand the operating and maintenance manual
before operating the machine.
The operating manual contains the following chapters:
INTRODUCTION
Chapter 1, SAFETY
Chapter 4, MAINTENANCE
If any part of this manual cannot be understood, contact your supervisor or local distributor.
The operators and maintenance personnel must understand the instructions contained in this
manual. This is an essential condition for working safely with the machine.
The correct machine operation, use and regular maintenance are also essential elements to
provide the highest performance and safety.
Remarks:No part of this operating manual may be reproduced, stored in
electrical data systems, processed, copied or published in any way
without prior written approval by the manufacturer. All rights for copying,
distribution and translation are reserved by the manufacturer.
Remarks:Machines may be illustrated in this manual equipped with
accessories.
0-2
INTRODUCTION
0-3
INTRODUCTION
0-4
CHAPTER1- SAFETY
1-1
Chapter 1
SAFETY
SAFETY
Closely observe the recommended precautions and instructions for safely operating the
machine.
DANGER
(Red background)
WARNING
(Orange background)
CAUTION
(Yellow background)
NOTICE
(Blue background)
REMARKS: Remarks contain information for the efficient application of the machine.
PLEASE NOTE: Contains general information not connected with danger.
1-2
SAFETY
Chapter 1
The manufacturer cannot predict all potential hazards which can expose personnel
to danger. The warning symbols in this manual and the warning symbols on the
machine cannot advert all potential hazards.
The machine has been designed and manufactured in accordance with the current
norms, standards and recognised safety regulations. In spite of this, improper use
can lead to serious injury or even death of the operator or other persons. Damage
may also occur on the machine, to property and the environment.
All locally prevailing accident prevention regulations, directives and laws must be
strictly observed. These still apply although they are not specifically mentioned in this
manual. The user is solely responsible for ensuring these regulations, directives and
laws are strictly complied with.
1-3
Chapter 1
SAFETY
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.
1-4
SAFETY
Chapter 1
The machine is only used in a perfect functional and operating condition and with all
safety devices supplied with the machine.
All maintenance and service intervals are strictly adhered to. The correct function of
all safety devices must be regularly checked.
Only fully qualified persons carry out work on the machine. The personnel assigned
to work on the machine must be suitably trained and have adequate experience in
handling such equipment and qualified for performing the respective work. The
manufacturer offers suitable training courses for the personnel.
Any work on the machine's electrical system and equipment may only be performed
by a trained assistant electrician or a similarly trained person whereby they are
supervised and controlled by a fully trained and qualified electrician. This work must
be carried out in accordance with your locally prevailing electro-technical regulations
and directives.
Ensure that the gas heating system is operated and maintained by fully qualified and
authorized personnel who have been thoroughly instructed in the operation and
maintenance of the system and from whom it is expected that they will carry out the
work in a reliable manner.
Work on the machine's chassis, the brakes, the hydraulics and the steering system
may only be carried out by fully qualified personnel who have been appropriately
trained and have the required skills.
The personnel must be regularly trained in all matters of occupational health and
safety as well as environment protection. The personnel must be aware of and
observe all regulations concerning hazardous goods and materials. All locally
prevailing laws and regulations must be complied with.
The personnel must be told to read the operating manual and especially the safety
instructions included in the manual.It is the owner's / contractor's responsibility to
ensure his personnel has read and understood the operating manual.
The required protective clothing must be made available to the personnel for
operating, servicing and repairing the machine. The personnel must be instructed to
wear protective clothing at all times.All necessary safety precautions must be taken
on the job-site.
1-5
Chapter 1
1-6
SAFETY
The contractor / owner must clearly delegate responsibilities to his personnel for
setting up, operating, servicing and repairing the machine. The operator must be
authorised to reject instructions from third persons which may jeopardise safety.
SAFETY
Chapter 1
Thoroughly read the operating manual.You must be able to operate the machine
safely and know and understand all procedures for safely carrying out maintenance
work.
Always take the prescribed safety precautions and wear protective clothing for your
personal protection.
Operators and maintenance personnel must exercise extreme caution and foresight
when performing work to recognise potential hazards.
Operators with long hair must tie it into a bun or wear a protective helmet; wear
overalls that fit snug to the body and remove all rings and jewellery.Loose overalls,
long hair and jewellery may become entangled in the machine. This can lead to
serious injuries and fatal accidents.
Contact your supervisor or your nearest authorised distributor if you have any
questions concerning the safe handling and maintenance of your machine. NEVER
WORK ON AN ASSUMPTION, carry out an inspection.
The machine is only used in a perfect functional and operating condition and with all
safety devices supplied with the machine.
Immediately stop the machine if a functional fault occurs. The faulty function must be
immediately reported to your supervisor / responsible department.
Never perform maintenance work when the engine is running and the hydraulics are
under pressure. Before starting any work on the machine, ensure it cannot be
switched on, secure it against rolling off and lower the screed.
Modifications or alterations affecting the safety of the machine may not be carried out
without prior approval by the manufacturer. This applies to the installation and
adjustment of safety devices and valves as well as welding work on load bearing
assemblies and elements.
Always adhere to the specified intervals for service and maintenance work.
1-7
Chapter 1
SAFETY
CAUTION
Precaution
Engine exhaust
CAUTION
1-8
Precaution
Anti-freeze solution
(water cooled engine)
Hydraulic oil
Engine oil
Grease
Corrosion protection
SAFETY
Chapter 1
Material
Precaution
Fuel
Battery water
Gear oil
1-9
Chapter 1
SAFETY
DANGER
The gas heating system may only be operated and serviced by qualified and
authorised personnel who have been specially trained in the operation and
maintenance of such systems.
Ensure the complete gas heating system is checked by a fully qualified and
authorized person as follows:
Before using the gas heating system for the first time, ensure that it is correctly
installed and has no gas leaks.
Check the working safety of the system on completion of all maintenance and
repair work.
Check the working condition, function, installation and gas leaks in the system if
it has been out of operation for more than one year.
1-10
Your locally prevailing regulations for checking gas bottles still apply and are not
effected by this chapter.
All gas connections must be checked for leakage and damage.Only use gas
detectors approved for gas systems.Searching for gas leaks with a naked flame is a
deadly peril and listening for escaping gas is not a safe method either. Do not use
the gas heating system if the hoses or connections are porous or damaged.
Only operate the gas heating system in open and well ventilated areas.
Protect the gas heating system from direct sun rays and other sources of heat (max.
50 C). Cover the gas bottles with the canopies supplied with the paver.
Close the valves on the gas bottles by turning them clockwise when the gas heating
system is not in use, e.g. during breaks in paving and when working on the system.
Disconnect, remove and properly store the gas bottles during longer standstill times.
The gas heating system must be switched off during cleaning work.
SAFETY
Chapter 1
When performing any work on the gas heating system, ensure there are no sources
of ignition within a radius of 10 metres.Do not smoke, do not ignite any naked flames
and do not switch on any electrical appliances within this safety radius (danger of
flashover).
Safely mount the gas bottles on the paver using the supports and brackets provided
and ensure they are secured against rotating or falling over. Only withdraw gas from
the bottles when they are in an upright position.
During operation, the gas bottles should not be allowed to become under-cooled as
this may cause an interruption in the flow of gas. Icing on the bottles caused by an
exceptionally high withdrawal of gas must be allowed to thaw off using warm air or
warm water with a temperature not exceeding 50[C]. Never use a naked flame, red
hot objects or convector heaters to thaw off the gas bottles. Icing must not be
hammered off the gas bottles or removed mechanically in a similar manner.
When replacing hoses, ensure the new hoses and connections are suitable for gas
heating systems and are routed in such a way to protect them from chemical, thermal
and mechanical damage.
The gas heating system may only be operated using a pressure control valve with
integrated leak tester and hose rupture safety control.
Leaky gas bottles must be immediately removed from the danger zone, if this is
possible without submitting yourself to danger and be appropriately marked.
Never operate the gas heating without the ventilation system correctly installed and
keep the ventilation intake and outlet apertures free from blockages to ensure an
adequate natural ventilation.
Fire and explosion precautions must be taken if the heating system is operated in
buildings or areas where explosive gases can be reckoned with. Keep all
combustible objects and cleaning cloths which may ignite away from hot parts on the
heating system.
Parts in the heating system which are subject to wear and deterioration must be
renewed after 8 years at the latest. An exception to this rule is when a specialist
confirms their perfect working condition.
In case of fire, remove the gas bottles to a safe area and keep them cool but do not
subject yourself to danger.
1-11
Chapter 1
SAFETY
CAUTION
1-12
11
Ignition electrode
12
Thermo element
13
14
Sieve
15
Solenoid valve
16
Start button
17
Stop button
18
Safety valve
19
10
Burner
20
SAFETY
Chapter 1
DANGER
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.
Extinguish all naked flames, cigarettes and other sources of ignition in the
vicinity.
If there is a danger that escaping gas cannot be brought under control or there
is a danger of fire in the area of the heating system, immediately alarm the fire
brigade and try to extinguish the fire yourself but do not subject yourself to
danger. Immediately clear the danger zone of all persons.
1-13
Chapter 1
SAFETY
DANGER
1-14
Do not touch any operating controls or any other parts of the machine.
Only leave the machine when you are absolutely sure that the damaged cable
is dead.
2-1
Chapter 2
WARNING
In the interest of your own safety and the safety of others, you must
thoroughly read and understand this chapter before operating the
machine.
2-2
Chapter 2
MACHINE OVERVIEW
Illustration 1:
Table 1:
Pos.
Description
Function
Sun roof
Road Scrapers
Crawler Unit
10
Fuel Tank
11
Distributor augers
12
Towing arms
13
Paving screed
14
15
16
2-3
Chapter 2
OPERATOR'S PLATFORM
Illustration 2
Table 2:
Pos.
2-4
Description
Function
Guide tube
Chapter 2
OPERATOR'S SEAT
STANDARD SEAT
CAUTION
Sudden movements of the seat will cause injuries. Ensure that all
adjusting levers lock into position after adjusting the seat. Only adjust
the seat when the machine is at a standstill.
Illustration 3:
Table 3:
Pos.
Description
Function
Armrest
A-B
2-5
Chapter 2
DELUXE SEAT
CAUTION
Sudden movements of the seat will cause injuries. Ensure that all
adjusting levers lock into position after adjusting the seat. Only adjust
the seat when the machine is at a standstill.
Illustration 4:
Table 4:
Pos.
Description
Function
Seat heating
Front LH switch: Seat heating ON /
OFF
Rear RH switch: Backrest heating ON /
OFF
2-6
Chapter 2
CONTROL PANEL
Illustration 5:
Table 5:
Pos.
Illustration
Description
Function
A1
Control lamp,engine
oil temperature
Shows the temperature of the engine oil. The indicator needle must
be in the green range during operation. If the needle moves into the
red range, immediately stop the
engine and eliminate the cause of
overheating (e.g. engine overloaded, loss of coolant, dirty radiator).
A2
A3
2-7
Chapter 2
Pos.
2-8
Illustration
Description
Function
A4
Operating hour
meter
A5a
Road lights
A5b
Flashing direction
indicators
A5c
Battery charging
lamp
A5d
A6a
A6b
A6c
Control lamp
hydraulic oil temperature
Pos.
Illustration
A6d
Chapter 2
Description
Function
A7
A8a
Toggle switch,
tampers
2-9
Chapter 2
Pos.
A8b
Illustration
Description
Potentiometer,
heavy duty tampers
Function
Potentiometer for setting the
tamper frequency.
Potentiometer only with heavy
duty tampers (variable displacement pump); refer to 227Page,
Pos. 2.
A9
Speed potentiometer
A10
A11
Emergency STOP
button
A12
2-10
Pos.
Illustration
A13
Chapter 2
Description
Toggle switch,
speed stage selector
switch
Function
Switch for selecting the required
speed stage.
LH Position (L): Paving speed
(Low, 0 - 16 m/min)
RH Position (H): Transport speed
(High, 0 - 60 m/min)
The paver will automatically stop
when changing speed stages onthe-run. Thereafter, turn the speed
potentiometer to start the paver
again.
A14
A15
2-11
Chapter 2
Pos.
A16
Illustration
Description
Toggle switch, RH
tow point
Function
Toggle switch for altering the paving thickness on the RH side.
The tow point can only be manually adjusted when the toggle switch
(A35) for the levelling system has
been moved to the MAN mode.
Centre Position: neutral
Move the switch to the rear (upwards): Increase the mat thickness
Move the switch to the front
(downwards): Reduce the mat
thickness
A17
Toggle switch, RH
auger operating
mode
A18
Toggle switch, RH
Auger ON/OFF control
A19
Toggle switch, RH
conveyor operating
mode
RH conveyor ON / OFF.
Centre Position: Conveyor is
switched OFF.
LH Position (MAN): Conveyor is
manually switched ON and OFF.
RH Position (AUTO): The conveyor is controlled by the RH paddle type control switch.
2-12
Pos.
Illustration
A22
Chapter 2
Description
Toggle switch, hopper wings
Function
Hopper wings open and close.
Centre Position: neutral
Move the switch to the rear (upwards): Close the hopper wings.
Move the switch to the front
(downwards): Open the hopper
wings.
Mechanically secure the closed
hopper wings with the locking bolts
when transporting the paver.
A21
Toggle switch,
Auger reverse mode
A22
A23
2-13
Chapter 2
Pos.
A24
Illustration
Description
Ignition switch
Function
Starting and stopping the engine
From left to right:
Position P: Parking position
(P), the ignition key can be removed
Position 0: Engine cut-out (before stopping the engine, let it run
for approx. 5 minutes without load
at a higher speed to cool down).
Position 1: Switch on the ignition; the control lamps will illuminate
Position 2: Start the engine
To start the engine, the drive lever
(A25) must be in the neutral position.
A25
Drive lever
2-14
Pos.
Illustration
A26
Chapter 2
Description
Steering potentiometer
Function
For steering the paver
Centre Position: The paver travels straight ahead.
Rotate to the left: The paver will
travel in a left turn
Rotate to the right: The paver will
travel in a right turn
A27
Toggle switch,
screed assist
(Option)
2-15
Chapter 2
Pos.
A28
Illustration
Description
Toggle switch,
screed anti-climbing
lock (Option)
Function
Screed anti-climbing lock ON /
OFF.
If required, the screed transport
cylinders can be hydraulically
locked in position to prevent the
screed from raising.
The anti-climbing lock prevents
the screed from climbing up and
over paving material which has
cooled down in front of the screed
when the machine starts moving
again after a stop in paving work.
The screed anti-climbing lock will
only function with the drive lever
moved to the forward travel position and the screed switched to the
floating mode.
LH Position (ON): The screed
anti-climbing lock will be switched
on for approx. 10 seconds when
the machine starts paving.
RH Position(OFF): The screed
anti-climbing lock is switched off.
A29
Toggle switch,
screed floating
mode
A30
2-16
Control lamp,screed
floating mode
Pos.
Illustration
A31
Chapter 2
Description
Toggle switch,
Screed raise / lower
Function
Screed raise and lower
Move the switch to the
rear:Screed raise
Move the switch to the front
(downwards): Screed lower
A32
Toggle switch, LH
auger operating
mode
A33
Toggle switch, LH
Auger ON/OFF control
A34
Toggle switch, LH
conveyor operating
mode
LH conveyor ON / OFF.
Centre Position: Conveyor is
switched OFF.
LH Position (MAN): Conveyor is
manually switched ON and OFF.
RH Position (AUTO): The conveyor is controlled by the LH paddle type control switch.
2-17
Chapter 2
Pos.
A35
Illustration
Description
Toggle switch, Levelling system
Function
Levelling system control.
Centre Position: The levelling
system is switched OFF.
LH Position (MAN): The levelling
system will function when the machine is paving and at a machine
standstill. This permits the mat
thickness to be corrected using the
toggle switches (A16) for the RH
tow point and (A37) for the LH tow
point. We recommend to use this
position only for setting up the levelling system at the start of paving
work.
RH Position (AUTO): The levelling system will control the mat
thickness during paving work.This
position is recommended for paving.
A36
A37
Toggle switch,LH
tow point
2-18
Pos.
Illustration
A38
Chapter 2
Description
Lever, engine speed
control
Function
Throttle lever for engine speed.
Move the lever upwards: Increase the engine speed
Move the lever downwards: Reduce the engine speed
2-19
Chapter 2
Table 6:
Pos.
B1
Illustration
Description
Button switch,
Increase mat thickness
Function
Increase the angle of attack on the
LH and RH side of the screed to increase the mat thickness.
Ensure the tow points are not adjusted to opposite limit stops (one
tow point to the upper and one tow
point to the lower limit stop). This
will cause undue torsion and twisting on the screed. The maximum
permissible difference in height
between the LH & RH mat thickness scales must not exceed 100
mm.
Never operate the tow point adjustment when the screed is raised
and secured in the transport locks
otherwise damage will occur to the
locking device.
2-20
Pos.
Illustration
Chapter 2
Description
Function
B2
Button switch,
Reduce the mat
thickness
B3
B4
Button switch,Vario
screed extend
B5
B6
B7
Pressure switch
STOP material flow
B8
2-21
Chapter 2
STORAGE COMPARTMENTS
Illustration 7:
Table 7:
Pos.
2-22
Description
Location
Chapter 2
FUEL TANK
Illustration 8:
Table 8:
Pos.
1
Description
Filler cap
Function
Topping up with Diesel fuel; new pavers
are supplied with the ignition key for the
ignition switch (A24) fastened on the
inside of the filler cap
2-23
Chapter 2
CAUTION
The grease container must never run empty otherwise the pump must be deareated.
Illustration 9
Table 9:
Pos.
2-24
Description
Function
Lubricating point
Safety valve
Grease gun
Chapter 2
Table 10:
Pos.
1
Description
Mat thickness scales
Function
Indicates the approx. paving thickness
2-25
Chapter 2
CAUTION
Table 11:
Pos.
2-26
Description
Function
Stop valve
Spraying lance
Level indicator
Filler cap
Chapter 2
Table 12:
Pos.
1
Description
Potentiometer, vibrators
Function
Setting the vibrators
Rotate clockwise: reduce the vibrator
speed
Rotate anti-clockwise: increase the vibrator speed
2-27
Chapter 2
CAUTION
Always close both ball cocks on the levelling cylinders on both sides of
the paver. If you only switch off the levelling cylinder on one side of the
paver, the screed will be subject to excess torsion and will be damaged.
Illustration 13:
2-28
Chapter 2
Table 13:
Pos.
1
Description
Ball cock, levelling cylinder
Function
Switch off the hydraulic circuit for the RH
or LH levelling cylinder n case of a
breakdown (Location:on the RH and LH
levelling cylinders).
Lever position vertical (as illustrated): Normal position, the ball cock is
open, the hydraulic is switched on and
the levelling cylinder is ready for operation
Lever position horizontal: The ball
cock is closed, the hydraulic circuit is
blocked; the levelling cylinder is
switched off. Levelling is not possible.
2-29
Chapter 2
DANGER
At the end of paving work, close the valves on the gas bottles, the
distributor and on the gas burners.
Before transporting the paver, close the valves on the gas bottles,
remove the gas hose with pressure reducer and fit the protective caps on
the gas bottles.
2-30
Chapter 2
before switching off the paver's ignition, ensure that the toggle switch for the standard
gas burners is moved to Pos. ON (I) to ensure a burner run-down.
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
2-31
Chapter 2
Table 15:
Pos.
2-32
Description
Function
Chapter 2
ELECTRICS
BATTERY MASTER SWITCH
CAUTION
Switch off the power supply with the battery master switch:
before all maintenance and repair work on the paver to avoid short circuits.
at the end of paving work to ensure all users have been switched off.
Illustration 16:
Table 16:
Pos.
1
Description
Battery Master Switch
Function
Switch off the power supply at the end of
work
Vertical position: Power supply
switched on (illustration refers)
Horizontal position: Power supply is
switched off (as an additional anti-theft
measure, remove the plastic key from
the master switch in this position at the
end of work).
2-33
Chapter 2
WORKING LIGHTS
Illustration 17:
Table 17:
Pos.
2-34
Description
Function
Working lights
Chapter 2
Table 18:
Pos.
Description
Function
24-V socket
24-V socket
24-V socket
Fuse box
24-V socket
Socket for the gas burners on the Variomatic screed - basic width
24-V socket
2-35
Chapter 2
Table 19:
Pos.
2-36
Function
FUNCTION
24-V socket
24-V socket
24-V socket
24-V socket
Chapter 2
Table 20:
Pos.
Function
FUNCTION
24-V socket
24-V socket
24-V socket
2-37
Chapter 2
Table 21:
Pos.
2-38
Description
Function
Fuses
Chapter 2
Table 22:
Pos.
Description
Function
Switch cabinet
2-39
Chapter 2
Table 23:
Pos.
2-40
Description
Function
Socket
CHAPTER 3 - OPERATION
3-1
Chapter 3
OPERATION
OPERATION
WARNING
CAUTION
3-2
OPERATION
Chapter 3
Use the handrails and steps when climbing up onto and leaving the machine and
keep the working area free from dirt and ice.
Only put the machine into operation when all protective and safety devices are
correctly installed and fully functional (e.g. working lights, removable safety systems,
noise protection devices and exhaust system).
The operator must be well acquainted with his working surroundings. Observe any
obstructions and other potential hazards in the working area and be aware of these
sources of danger.
The paving crew must be acquainted with and use any hand signals required for the
working process. Furthermore, a responsible person must determine the hand
signals to be used.
The operator must not leave the operator's platform when the engine is running. Do
not jump onto or down from the machine when it is moving.
Observe all warning and control lamps and indicators when stopping and starting the
machine and be aware of any irregularities.
Switch on the working lights during poor visibility and twilight hours.
Before putting the machine into motion, ensure there are no persons or obstructions
in the direction of travel or within the danger zone of the screed. Observe the paving
width on both sides of the extended Variomatic screed.
Use extreme care and added caution when working on narrow job-sites or paving
jobs with a high volume of traffic.
Use the drive lever and not the engine throttle lever to control the machine's
speed.Do not accelerate a cold engine to a higher speed.
Ensure there is adequate headroom before driving the machine through bridges and
tunnels, underneath overhead cables and across bridges.
Sound the warning horn to warn persons in the vicinity before driving off and putting
machine parts into motion. Give other persons sufficient time to leave the danger
zone before moving the machine.
Before leaving the operator's platform, secure the machine against unintentional
movement and unauthorised access. Remove the ignition key.
3-3
Chapter 3
OPERATION
Ensure there is always an adequate safety distance between the paver and
overhead electric cables. Otherwise a deadly conduction of electric current is
possible. The safety distance depends upon the voltage in the overhead cables and
the weather conditions.A conduction of current is possible at a distance of several
metres at a high voltage and damp air.
Switch off the power in the overhead cables if it is not possible to keep an adequate
safety distance.
If the machine makes contact with an electric power cable in spite of taking these
precautions, refer to the procedures outlined in Chapter 1 Safety precautions when
the machine touches live electric cables, Page 1-14.
Ensure the paving crew is not exposed to health risks when working in the vicinity or
in contaminated areas such as waste disposal dumps etc.
3-4
Paving in the vicinity of railway lines with passing rail traffic is subject to increased
danger which can lead to fatal accidents.
Only start work after obtaining permission from the railway authorities and after all
necessary safety measures have been taken.
Pay continuous attention to the railway traffic and to the railway staffs instructions,
in order to immediately remove machine and persons out of the danger zone.
Ensure there is always an adequate safety distance between the paver and
overhead electric cables. Otherwise a deadly conduction of electric current is
possible. The safety distance depends upon the voltage in the overhead cables and
the weather conditions. A conduction of current is possible at a distance of several
metres at a high voltage and damp air.
OPERATION
Chapter 3
PAVING ON SLOPES
Special safety precautions must be taken, such as securing the paver with a winch
cable, when working on slopes where there is a danger of the machine toppling over
or sliding away.
PAVING ON BRIDGES
Ensure the weight bearing capacity of the bridge is sufficient to carry the weight of
the paver and other machinery and equipment required for paving work.
3-5
Chapter 3
OPERATION
WARNING
Only put the machine into operation when you are absolutely sure that it
is a perfect working condition. It is not permitted to use the machine if
you know it is faulty. Rectify the faults or have them repaired by a service
technician or your local distributor.
Thoroughly check the machine before putting it into operation.
1. Ensure that all daily maintenance work is carried out.(refer to Daily procedure
at the end of paving work, page 3-61.) If necessary, top up fluids and complete
maintenance work.Pay particular attention to:
Fuel level
Coolant level
2. Check the complete machine for loose, worn and missing parts. This specially
applies to all safety devices.Renew any parts if necessary.
3. Check the following components for leakage: Gas heating system, fuel tank,
fuel lines, hydraulic lines, hoses, filler necks, drain plugs, pressure valves,
exhaust pipe, engine and components installed underneath the paver.
4. Ensure that the first aid box and operating manual are stored on the machine.
5. Remove all items not required for paving work.
6. Clean the paver.In particular, remove all dirt, water or ice from the operator's
platform and in the vicinity of the external control panels which may pose a slip
hazard.
7. Carry out the work described in the following sections and ensure the work has
bee performed correctly.
3-6
OPERATION
Chapter 3
before starting maintenance and repair work to avoid short circuits and the paver
being started during work.
1. Open the paver's RH side door. Ensure the retainer catch locks into position
and prevents the door from closing.
2. Actuate the battery master switch 1:
To switch ON the power supply: Turn the plastic key to the vertical position (as
illustrated).
To switch OFF the power supply: Turn the plastic key to the horizontal position
(90 anti-clockwise).
3-7
Chapter 3
OPERATION
CAUTION
Only start the paver after the operator's platform has been set up to
ensure an optimum view of the working area and all platform components
have been safely secured.
During operation, all loose items must be removed from the paver as they
can cause serious accidents.
3-8
OPERATION
Chapter 3
The height of the paver can be reduced for transport on a vehicle by lowering the sun roof.
CAUTION
The sun roof must be raised and safely secured against lowering with the
bolts/nuts (2 and 3) for paving work. Otherwise it is not permitted to
operate the paver on account of the restricted headroom.
Before lowering the roof, the windscreen (if fitted) must be raised (refer to
Chapter 3 Windscreen (Option), Raising and Lowering, Page 3-13).
After the roof has been lowered, it must be secured against raising with
the bolts/nuts 3.
Illustration 5
3-9
Chapter 3
OPERATION
3-10
OPERATION
Chapter 3
The height of the paver must be reduced for transport on a vehicle. For this reason, remove
the exhaust pipe.
CAUTION
Do not start the paver without the exhaust pipe, otherwise poisonous
emission will be a health hazard to personnel in the vicinity.
Illustration 6
3-11
Chapter 3
OPERATION
The side curtains (1) protect the operator from rain and wind. Roll the side curtains up during
good weather to obtain a better all round view.
Illustration 7
Fitting the Side Curtains (1): Fit the side curtains (1) to the sun roof (2) and the roof struts
(3) as illustrated.
Removing the Side Curtains (1): Loosen and remove the side curtains (1) from the sun roof
(2) and roof struts (3) as illustrated.
3-12
OPERATION
Chapter 3
The windscreen is raised to the rear and underneath the roof for transport.The windscreen is
divided in the middle so that first one half and then the other half is raised.
Raising the Windscreen:
1. Loosen the centre bolt connection.
2. Loosen the outer bolt connection on the outer edge of one half windscreen.
3. Raise the windscreen half up and underneath the roof and secure the outer bolt
in the hole provided in the retainer plate.
4. Repeat step 3 with the other half of the windscreen.
5. Connect both raised halves of the windscreen in the middle with the connecting
bolt.
6. Ensure both windscreen halves are safely secured in the raised position.
CAUTION
3-13
Chapter 3
OPERATION
The operator's platform can be extended on both sides to improve the vision into the working
area. The platform must be retracted for transport on a vehicle to minimize the paver's width.
Illustration 8
3-14
OPERATION
Chapter 3
After extending or retracting the platform, you can extend or retract the seat console.
Illustration 9
3-15
Chapter 3
OPERATION
Position the control column according to the required sitting position. The control column may
only be positioned in the locking holes provided on the platform's floor plate (LH or RH side on
the extended or retracted platform). All other positions between these locking holes are not
permitted.
Illustration 10
1. Slightly tilt the control column to the rear (raise slightly) and cross slide it to the
required position on the guide rail depending on which side you have the best
view of the working area.
2. Lower the control column so that it locks into the hole 4 on the platform floor
plate. Ensure the control column has safely locked into position.
3. Open the cover 1 on the control panel (if necessary, remove the padlock 2).
3-16
OPERATION
Chapter 3
CAUTION
1. To and Fro Adjustment: Pull the lever (2) upwards to unlock the seat. Hold the
lever up and adjust the seat to the required position. Release the lever (2) to
lock the seat in position.
2. Backrest Adjustment: Pull the front lever (3) upwards. Sit on the seat and use
the weight of your body to adjust the seat's position. Thereafter, release the
lever (3) to lock the seat in position.
3. Operator's Weight Adjustment: The weight setting can be varied with the
lever (1). The number on the scale should correspond to the weight of the
operator. The seat suspension is now set to the weight of the operator. First
press the lever to the lowest position to return it to the upper position.
4. Armrest Adjustment: Tilt the armrests to position A or B.
3-17
Chapter 3
OPERATION
CAUTION
Sudden movements of the seat will cause injuries. Ensure that all
adjusting levers lock into position after adjusting the seat. Only adjust
the seat when the machine is at a standstill.
Illustration 12:
1. To and Fro Adjustment: Pull the bar lever (2) upwards to unlock the seat. Hold
the bar lever up and push the seat to the required position. Release the bar
lever to lock the seat in position.
2. Height and Slope Adjustment: Unlock the seat by pulling the lever (3) on the
left-hand side upwards. Sit on the seat and use the weight of your body to
adjust the seat's position. Thereafter, release the lever (3) to lock the seat in
position.
3. Backrest Adjustment: Pull the lever (4) on the left-hand side upwards. Sit on
the seat and use the weight of your body to adjust the seat's position.
Thereafter, release the lever (4) to lock the seat in position.
4. Operator's Weight Adjustment: The seat's suspension can be adjust to the
weight of the operator by turning the knob (1) at the front of the seat. The
number which appears in the window must correspond to the weight of the
operator. The seat suspension is now set to the weight of the operator.
5. Armrest Adjustment: By turning the knob (5), you can adjust the height and
angle of the armrests.
6. Seat Heating (Option): Switch the seat heating on and off with the switch (6).
The engine must be running to operate the seat heating.
3-18
OPERATION
Chapter 3
CAUTION
the paver is in a perfect functional condition and equipped with all safety devices
supplied with the machine.
the operating personnel are fully qualified and fully acquainted with all controls and
instruments.
the platform is correctly equipped and set up, no access doors are open and no loose
objects are on the paver.
3-19
Chapter 3
OPERATION
Illustration 13
1. Return all operating elements on the control panel to the zero position: Toggle
switches to 0 or OFF position, drive lever (A25) to the centre neutral
position, speed potentiometer (A9) and steering potentiometer (A26) to 0.
2. Check that the emergency STOP button (A11) has been pulled upwards and
the drive lever (A25) is in the centre neutral position. If the control lamp
"emergency STOP" (A6b) illuminates, press the button switch (A12) to release
the emergency STOP.
3. Move the engine throttle lever (A38) to 1/4 speed.
4. Start the engine:
Insert the ignition key in the ignition switch (A24). (The paver is supplied with the
ignition key fastened to the inside of the filler cap).
Turn the ignition key to position 2 "Engine Start". Release the key as soon as the
engine starts.
Remarks: Do not actuate the starter for more than 20 seconds as the
starter motor will overheat. If the engine cannot be started at the first
time, wait for 2 to 3 minutes before attempting another start.
5. With the exception of the spring loaded brake (A6d), check and ensure that all
other control lamps are extinguished. If not, immediately switch off the engine
and rectify the fault.
6. Move the engine throttle lever (A38) to the lowest speed.
7. Let the engine run warm for a short time to bring the hydraulics and the engine
up to operating temperature. However, ensure the engine does not run for more
than 10 minutes at idling speed.
3-20
OPERATION
Chapter 3
WARNING
Strictly observe the following instructions when jump starting the engine.
Ignoring these instructions will lead to accidents, serious injuries and
possibly death.
Lead acid batteries develop explosive gases when being charged. Keep naked
flames and sparks away from batteries.
Do not start the machine by connecting the jumper cable to the starter motor or
starter solenoid switch because this will bridge over the safety device installed on the
machine. There is also a danger of the machine being put into motion and running
over the people carrying out the jump start.
Never attempt to jump start a machine with frozen batteries as this will cause the
batteries to explode.
Before jump starting the machine, disconnect all electronic equipment (e.g. levelling
system) from the power supply as this will be damaged by peaks in the voltage.
3-21
Chapter 3
OPERATION
Illustration 14:
3-22
OPERATION
Chapter 3
CAUTION
1. Return all operating elements on the control panel to the zero position: Toggle
switches to 0 or OFF position, drive lever (A25) to the centre neutral position,
speed potentiometer (A9) and steering potentiometer (A26) to 0.
2. Move the engine throttle lever (A38) to the lowest speed. Depending on the
previous load, let the engine run for a time to cool down (but not longer than 10
minutes).
3. Turn the key in the ignition switch (A24) to the "P" position (Park).
4. Remove the key before leaving the paver.
3-23
Chapter 3
OPERATION
CAUTION
3-24
Check the fuel level on the control panel. Refuel if necessary (Chapter 3 Refuelling
the Paver, Page 3-30)
Switch on the working lights during poor visibility and twilight hours.
Inspect and become acquainted with the immediate working area. Pay particular
attention to all possible hazards such as potholes in the road surface, slopes and
inclinations, underground culverts, manhole covers, drainage ditches, kerbstones
and/or roads.
Before putting the machine into motion, ensure there are no persons or obstructions
in the direction of travel or within the danger zone of the screed. Observe the paving
width on both sides of the extended Variomatic screed.
When steering track mounted machines, the front and rear will swing out when
cornering. Therefore, keep a safe distance to persons, buildings and other obstacles.
OPERATION
Chapter 3
CAUTION
When driving the paver on roads and job-sites there is a danger of fatal
accidents and serious damage. Closely observe the following when
driving the paver:
Observe the extended width of the screed when transporting the paver on job-sites.
If necessary, ballast must be placed in the hopper to act as a counter weight to the
screed. Ballasting is not necessary if the paver is driven at a very slow speed.
When driving the paver on the job-site, disconnect the gas bottles and fit the
protective caps (Chapter 2 Screed Heating System (Option), Page 2-30).
Switch on the warning beacon and mount warning plates if required by your locally
prevailing traffic code.
Illustration 16
1. Close and lock the hopper wings (Chapter 3 Hopper Wings, Open and Close,
Page 3-36).
2. Dismantle any screed extensions (refer to the documentation for the screed).
Reduce the Vario extensions to the minimum width on Variomatic screeds
(Chapter 3 Variomatic Screed, Extend and Retract, Page 3-39).
3. Dismantle any other components which may be an obstacle or accident prone
during transport. For example, the auger extensions or direction indicator.
4. Raise and secure the screed in the transport locking device (refer to Chapter 3
Screed Transport Lock, Page 3-36).
5. raise the augers to the uppermost position (Chapter 3 Auger Height
Adjustment, Page 3-42).
3-25
Chapter 3
OPERATION
Push the drive lever (A25) forwards and the paver will travel forward.
Pull the drive lever backwards and the paver will travel in reverse.
Return the drive lever to the centre neutral position to stop the paver.
3-26
OPERATION
Chapter 3
TURNING ON-THE-SPOT)
Illustration 17
The function of turning on the spot will not operate if the electronic control for the travel drive
is faulty.
1. Stop the paver by returning the drive lever (A25) to the neutral zero position.
2. Move the toggle switch (A13) to the low paving speed stage (L).
3. Turn the steering potentiometer (A26) to the centre zero position.
4. Move the toggle switch "Turning on the spot" (A14) to position "1" and keep it
in this position.
5. Ensure nobody is in the paver's slewing range and sound the warning horn to
warn persons in the danger zone.
6. The paver will turn on the spot as soon as you turn the steering potentiometer
(A26):
Turn the paver to the right: Rotate the steering potentiometer (A26) to the right
Turn the paver to the left: Rotate the steering potentiometer (A26) to the left
The more you rotate the potentiometer, the faster the paver will turn.
7. As soon as the paver has reached the required direction, return the steering
potentiometer (A26) to the centre zero position and release the toggle switch
"Turning on the spot" (A14).
3-27
Chapter 3
OPERATION
Operating the paver in auxiliary control will be the same as in normal control, i.e. use the drive
lever (A25, 27Page), the speed potentiometer (A9, 27Page) and the steering potentiometer
(A26, 27Page) refer to Driving the Paver on Roads and Job-sites, page 3-25.
Remarks: When operating the paver in the auxiliary control mode,
acceleration and braking will react a lot slower. Therefore, we
recommend to start and stop the paver by rotating the speed
potentiometer (A9, 27Page).
Starting the paver
1. Rotate the speed potentiometer (A9, 27Page) to the centre zero position.
2. Move the drive lever (A25, 27Page) to the required direction of travel.
3. Rotate the speed potentiometer (A9, 27Page) to accelerate the paver to the
required speed.
Stopping the paver
Remarks: Only stop the paver by pressing the emergency STOP button
(A11, 27Page) in cases of danger.
1. Rotate the speed potentiometer (A9, 27Page) to the centre zero position.
2. Return the drive lever (A25, 27Page) to the centre zero position.
3-28
OPERATION
Chapter 3
CAUTION
Cordon off the working area. When preparing the paver for operation,
only those persons involved with setting-up work may enter the working
area.
During operation, the paver's engine may only be started when it is
absolutely necessary for paving work. A running engine is an increased
risk of accidents. Therefore, work with exceptional caution.
NOTICE
Drive the paver to its working position parallel to the lane to be paved.
Refuel beforehand if necessary.
3-29
Chapter 3
OPERATION
CAUTION
Fire risk: Do not smoke and avoid sparks and naked flames when
refuelling.
Switch off the engine and ensure a good ventilation when refuelling.
Wear protective clothing to protect your eyes, hands and respiratory passages.
Do not spill any fuel when refuelling the machine. Immediately remove any fuel
spilled.
NOTICE
Never let the fuel tank run dry, otherwise the entire fuel system must be
dearated. Refuel the paver at the end of a working shift to prevent
condensation forming in the tank.
3-30
OPERATION
Chapter 3
Illustration 19
3-31
Chapter 3
OPERATION
Basic Augers
Conveyors including the conveyor drive shaft and the conveyor idler shaft.
Ensure the grease container is adequately filled with grease when putting the paver into operation. Before and after paving work, activate the rapid lubrication function by pressing the illuminating button switch H10 for the "Rapid Lubrication".
CAUTION
3-32
Only operate the central lubrication with the pressure relief valve installed in the
system and ensure the valve is functional. If grease appears out of the pressure relief
valve, at least one lubrication circuit has a blockage and the respective lubrication
point will no longer be supplied with grease. Immediately remove the blockage.
The grease container must never run empty otherwise the pump must be deareated.
OPERATION
Chapter 3
Illustration 20
1. Check the MIN and MAX level marks on the grease container to ensure there
is sufficient lubricant in the system. If the level is too low:
Fill the grease gun (4) with grease according to the list of "Fuel, Oils &
Lubricants".
Insert the grease gun (4) on the connection and pump grease into the container
until the MAX level mark has been reached.
2. Start the engine and press the illuminating button switch for a rapid lubrication
(A10, 27Page) on the control panel. The control lamp illuminates during the
lubrication process.
NOTICE
Carry out point 2 before and after paving work.
3-33
Chapter 3
OPERATION
1. Whenever necessary, clean off any bitumen and dirt which has accumulated
on the truck buffer rollers (5).
3-34
OPERATION
Chapter 3
WARNING
The road scrapers must be raised for transporting and loading the paver.
Otherwise they will be damaged.
Illustration 22he
The road scrapers (2) should touch the ground when the screed is in the raised position. By
raising the screed, the paver's centre of gravity will be transferred to the rear of the machine.
1. Adjust the height of the road scraper (2) with the adjusting screw (4) as
previously described.
3-35
Chapter 3
OPERATION
WARNING
Close and lock both hopper wings before transporting the paver.
Otherwise there will be an increased risk of danger because the hopper
wings protrude beyond the basic width of the paver.
Illustration 23
The hopper (1) is fitted with two wings. The hopper serves as a bunker for the paving material
during paving work. The hopper wings can be closed to completely empty the hopper during
paving work. The hopper wings must always be opened for the dump truck to charge the hopper.
Hopper Wings, Open and Close
1. Use the levers (2) to release both hopper wings. Both locking hooks (3) must
be completely free.
2. Ensure there are no persons or obstacles in the danger zone and sound the
warning horn to warn other persons of a potential danger.
3. Use the toggle switch A22 on the control panel to open and close the hopper
wings.
4. Use the levers (2) to lock the hopper wings in the closed position. The LH and
RH locking hooks (3) must safely lock into position.
3-36
OPERATION
Chapter 3
WARNING
The screed must be raised and secured in the transport lock before
loading and transporting the paver. Otherwise it may collide with the
ground and be damaged.
Never alter the position of the tow points if the screed is raised and
secured in the transport lock,i.e. do not actuate the toggle switches A16
and A37 (27Page). Otherwise the transport locking device will be
damaged.
Illustration 24
3-37
Chapter 3
OPERATION
3-38
OPERATION
Chapter 3
WARNING
1. Ensure there are no persons or obstacles in the danger zone and sound the
warning horn to warn other persons of a potential danger.
2. Press the button switch B4 or B5 and keep it pressed to extend or retract the
screed. Button switches B4 and B5 are located on both LH and RH external
control panels.
3-39
Chapter 3
OPERATION
WARNING
3-40
OPERATION
Chapter 3
Illustration 26 (example shown on a wheeled paver)
1. Extend the screed to its maximum paving width (refer to Variomatic Screed,
Extend and Retract, page 3-39).
2. Fit the tensioning cylinder (3) into the swivel bracket (4).
3. Connect the hydraulic hoses (5) to the tensioning cylinder.
4. To extend the ram on the hydraulic cylinder, swap the hoses (5) to opposite
connections. Thereafter, return the hoses to the correct connections.
5. Use the shackle (6) to connect the wire rope (1) to the eye on the tensioning
cylinder (3).
6. Bolt the connecting plate (2) to the end plate on the Variomatic screed.
7. Use the shackle (7) to fasten the wire rope (1) to the connecting plate. The wire
rope must be slack when the Variomatic screed and the tensioning cylinder are
both fully extended.
8. Move the toggle switch for the screed tensioning device to the ON position.
Both tensioning cylinders will tighten the wire rope and the screed is now
tensioned. The screed can be extended and retracted and the tension on the
wire rope remains constant.
Remarks: To dismantle the screed tensioning device, use the quick
action couplings (10) to swap the hydraulic hoses (5) to opposite
connections. The ram on the hydraulic cylinder can now be retracted.
Thereafter, return the hoses to the correct connections. Thereafter,
proceed in the reverse sequence described above.
3-41
Chapter 3
OPERATION
WARNING
3-42
OPERATION
Chapter 3
material in the auger channel. The augers are controlled by rubberised level switches, optionally by ultrasonic sensors, mounted on the auger outer bearings or LH and RH screed end
plates. The installation of the optional ultrasonic sensors is described in the operating manual
for the screed.
When paving thinner mats, the head of material in the auger channel can be reduced with the
augers in a lower position. This will reduce the shearing resistance on the screed and improve
traction.
WARNING
Wear gloves when working on the augers. The surfaces of the mix
conveyor system have sharp edges and may still be hot shortly after
paving work.
Ensure the augers do not collide with the ground when driving the paver
or loading it on a transport vehicle; this would lead to damage on the
augers. Raise the augers if necessary.
3-43
Chapter 3
OPERATION
1. If installed, disconnect the auger extensions with outer bearings from the basic
auger or use suitable lifting tackle to adjust their height (refer to Adjusting the
Height of Auger Extensions with Outer Bearings).
Remarks: The augers can be adjusted to any height within the adjusting
range if only the basic augers or the basic augers with auger extensions
but without auger outer bearings are used. In this case, the locating bolt
(1) will not be required and should be screwed into the adjacent hole for
safe keeping.
If the paver is fitted with auger outer bearings, the augers may only be
adjusted to the positions of -30 mm, 0 mm or +30 mm because the outer
bearing will only permit these adjustments. In this case, the locating bolt
(1) must be used.
2. If fitted, unscrew and remove the locating bolt (1) from the paver's rear wall.
3. To set the mechanical height adjustment, turn the barrel nut on the turnbuckle
(1) to raise or lower the augers by up to 30 mm from the zero position (the holes
for the locating bolt are positioned at -30 mm, 0 mm ,+30 mm).
To set the hydraulic height adjustment, raise or lower the augers by pressing
the switch (3) located on the LH seat console in the required direction.
4. If necessary (Remarks refer), secure the setting with the locating bolt (1).
3-44
OPERATION
Chapter 3
1. Slightly raise the outer end of the auger extension (5) with a suitable lifting
device. Do not exert any pressure on the bearing holder.
2. Loosen and remove the screws (4) from the bearing arm (3).
3. Raise or lower the auger extension with the lifting device until it has reached the
same level as the basic augers.
4. Replace the bearing arm (3) using the screws (4) and tighten the screws.
5. Remove the lifting device.
6. Repeat this procedure on the other auger side.
3-45
Chapter 3
OPERATION
WARNING
Switch off the Diesel engine before fitting any auger extensions.
Worn auger flights have sharp edges. Wear working gloves to protect
your hands.
Auger flights must be fitted to clean surfaces without free play. Protect
the ends of the auger shafts against wear by fitting the protective end
caps.
Fit the protective guards above the auger extensions. Protective guards
are supplied for the auger channel on manual screeds and for the height
adjustable channel plates on Variomatic screeds.
Auger extensions must be dismantled for transport. Otherwise there will
be an increased risk of danger because the auger extensions protrude
beyond the basic width of the paver.
3-46
OPERATION
Chapter 3
Illustration 30
The configuration of the auger extensions and protective guards for each particular paving
width is contained in the screed assembly plan.
1. Remove the protective end cap and screw from the basic auger shaft.
2. Connect the auger channel plate (4) to the paver's frame with the screws (2).
3. Connect the horizontal brace (3) between the channel plate (4) and the bracket
on the paver. Use the front connecting bolt (1) with safety clip on the paver and
the connecting bolt (5) on the channel plate to secure the horizontal brace.
4. use the turnbuckle (1) on the horizontal brace (3) to align the auger channel
plate with the paver's rear wall.
5. Use the vertical brace (7) to connect the auger channel plate (4) to the paver's
upper connecting lug. Secure the brace with the connecting bolts and safety
clips (6 & 8).
6. Adjust the turnbuckle on the vertical brace (7) so that the auger channel plate
is at an angle of 90 degrees to the paver's side wall.
7. Push the auger extensions (20) onto the basic auger. Ensure the pitch on the
basic auger and auger extension is the same.
8. Connect both coupling pieces (11) with the screw (10) and fit a 140 auger flight
(9) if required.
9. Fit the bearing arm (18) with the screws (19) to the support plate (17). The
auger extension must be adjusted to the same height as the basic auger.
3-47
Chapter 3
OPERATION
10. Fit the end cap (15) with a screw to the end of the auger extension shaft. A 140
auger flight (16) can be fitted with a M20 x 140 screw to improve the distribution
of the paving material.
11. Fit the hinged end plate (14) to the bracket (13) using the screws (12) as
illustrated.
12. Finally ensure that all protective guards (21) have been fitted and that they are
not damaged.
13. Stretch a piece of string across the entire width of the augers and check the
horizontal and vertical alignment of the auger extensions (20) with the basic
augers.
Remarks: With the exception of the auger flight pitch, the assembly of the
left- and right-hand augers is the same. The assembly of the adjustable
channel plate is the same for auger extensions with or without auger
outer bearings. The length of the adjustable channel plate and the auger
extensions vary according to the particular paving width.
Remarks: The adjustable channel plates achieve a more uniform
distribution of material in front of the screed. The pitch of the 140 auger
flight must be the same as the pitch on the basic auger. If mix segregation
occurs in the area of the auger outer bearing, it can be rectified by
swapping the flights.
Remarks: Fit a right-hand auger flight to the left-hand side and vice versa.
The same applies to the 140 auger flight at the end of the auger shaft.
3-48
OPERATION
Chapter 3
WARNING
Wear gloves when working on the augers. The surfaces of the mix
conveyor system have sharp edges and may still be hot shortly after
paving work.
Illustration 31
The auger control consists of two rubberized level switches. The level switches are mounted
at different positions depending on the paving width.
Small paving widths: Mount the rubberized level switches at position (1) as illustrated.
Large paving widths: Mount the rubberized level switches at position (2) as illustrated.
Remarks: The flat side of the rubberized level switches must always face
towards the paving material. Immediately renew faulty components with
genuine parts.
3-49
Chapter 3
OPERATION
WARNING
Switch off the engine and remove the ignition key before adjusting the
paddle type conveyor control switches. Wear gloves to adjust the paddle
type control switches.
Illustration 32
3-50
OPERATION
Chapter 3
WARNING
The direction indicator protrudes beyond the basic width of the paver
during paving work. Observe the extended width when driving the paver.
Illustration 33
1. Position the paver with the screed in the required width parallel to the reference
wire on the mat to be paved.
2. Loosen the clamp between the outrigger (6) and the indicator tube (7). Pull out
the indicator tube (7) to the required width.
3. Then retighten the clamp.
4. Loosen the fastening screw (11) and insert the angular tube (8) into the
indicator tube (7). Set the height of the angular tube (8) so that the two chains
(9) dangle either side of the reference wire.
5. Now tighten up the fastening screw (11). The clamps (10) holding the chains
(9) on the angular tube (8) can be repositioned on the tube as required.
6. Set the angular tube (8) so that it points outwards and to the front of the paver.
The angle between the indicator tube (7) and the angular tube (8) should be
approx. 105 degrees. If you work with only one chain (9), then this chain must
continuously dangle along the reference wire between the paver and the wire
itself.
3-51
Chapter 3
OPERATION
PAVING
SETTING THE OPERATING MODE AUTOMATIC
Illustration 34
3-52
OPERATION
Chapter 3
WARNING
The LH and RH screed towing arms must have almost the same setting.
The difference in the mat thickness must not exceed 10 cm. Otherwise the
screed will be distorted and damaged.
Illustration 35
When paving, the tow points must not ride against the upper or lower limit stops. Otherwise,
the hydraulic circuits for hopper open/close and screed raise/lower would no longer function.
If the tow points ride against the limit stops during paving work, the position of the screed towing arms must be altered relative to the paving screed so that the tow points have adequate
space to move between the limit stops. Further information is contained in the operating manual for the screed.
1. Ensure the toggle switch for the "levelling system" (A35) is not switched to
position 1; i.e. position MAN or position AUTO.
2. The tow points on both towing arms are adjusted using the toggle switch (A16)
"RH tow point" and (A37) "LH tow point".
Increasing the mat thickness: Move the toggle switches (A16 and A37) for the RH
and LH tow points upwards in the direction of the arrow until the required mat
thickness is reached.
Reducing the mat thickness: Move the toggle switches (A16 and A37) for the RH
and LH tow points downwards in the direction of the arrow until the required mat
thickness is reached.
3-53
Chapter 3
OPERATION
WARNING
1. Place square timbers or paving material underneath the screed. This will set
the screed to the required mat thickness.Add the degree of mix slump caused
by rolling.
2. Move the toggle switch (A29) "screed floating mode" to the "O" position.
3. Move the toggle switch (A31) "screed raise/lower" downwards to lower the
screed onto the timbers.
4. Move the toggle switch (A29) "screed floating mode" to the position "1". The
screed is now in the floating mode.
5. Ensure the control lamp (A30) "screed floating mode" illuminates. If this is not
the case, the screed is not fully lowered and is in the hydraulically blocked
position. An uneven mat would result if the machine paved with the screed in
this position. Therefore, manually lower the screed further downwards.
3-54
OPERATION
Chapter 3
NOTICE
We advise against starting paving work with a hydraulically blocked
screed and then switching to the floating mode after sufficient material is
forced underneath the screed. Normally, the screed would then not float.
3-55
Chapter 3
OPERATION
DANGER
3-56
OPERATION
Chapter 3
WARNING
3-57
Chapter 3
OPERATION
6. As soon as you move the drive lever (A25), the spring loaded brake will be
released and the paver will start moving.
Push the drive lever (A25) forwards and the paver will travel forward.
Return the drive lever to the centre neutral position to stop the paver.
3-58
OPERATION
Chapter 3
ference occurs between the mat thickness set on the paver (value on the tow point mat thickness scales) and the actual thickness of the mat being paved. The turnbuckles are set to a
value of "0" in the factory and increasing this value will achieve a thicker mat.
We recommend that the rear turnbuckles are not adjusted for paving mat thicknesses up to
approx. 10 cm. This means, that the screed's angle of attack will be adjusted by the tow points
to the mat thickness.
Rule of thumb: Value on the tow point thickness scales = 1.5 x the mat thickness.
Further instructions for adjusting the screed are contained in the screed's operating manual.
to the LH screed side: Move the toggle switch A21 "auger reverse rotation" to the left
(27Page).
to the RH screed side: Move the toggle switch A21 "auger reverse rotation" to the
right (27Page).
to switch off: Move the toggle switch A21 "auger reverse rotation" to the centre
position (27Page).
3-59
Chapter 3
OPERATION
LH Auger: Keep the button switch B3 pressed on the LH external control panel to
overmodulate the auger (27Page).
RH Auger: Keep the button switch B3 pressed on the RH external control panel to
overmodulate the auger (27Page).
The control valve is located inside the LH side door on the paver's rear wall. The pressure is
adjusted as follows (Pos. 1 refers):
3-60
OPERATION
Chapter 3
Mineral aggregates, dry-lean concrete and similar materials: Use a water hose.
12. Clean the paver. In particular, remove all dirt, water or ice from the operator's
platform and in the vicinity of the external control panels which may pose a slip
hazard.
13. If the paver is not equipped with the optional central lubrication system, grease
the auger bearings, the auger seals as well as the drive shafts and idler shafts
for the conveyors (Chapter 4 Grease Points, Page 4-29).
3-61
Chapter 3
OPERATION
DANGER
3-62
When choosing hoisting and lashing chains and slings, take the weight of the paver
(technical data refers) and the paving screed (refer to the screed's operating manual)
into consideration.
Chains and slings must comply with all locally prevailing accident prevention
regulations and must have sufficient lifting capacity to take the weight of the machine.
Only fasten hoisting and lashing slings and chains to the hoisting and lashing points
provided on the paver.
Observe all locally prevailing laws, regulations and the traffic code when driving or
transporting the paver on public roads.
Transport and loading work may only be carried out by qualified and authorized
personnel. Only experienced personnel should be assigned for attaching the crane
hooks to the machine and instructing the crane operator. The person giving the
instructions must be clearly seen by the crane operator.
Raise the augers to their highest position before transporting the paver.Chapter 3
Auger Height Adjustment, Page 3-42
Remove all loose objects from the paver before loading it by crane.
OPERATION
Chapter 3
Illustration 39
1. Close and lock the hopper wings (Chapter 3 Hopper Wings, Open and Close,
Page 3-36).
2. Retract the operator's platform, seta console and sun roof and remove the
exhaust pipe (Chapter 3 Setting up the Operator's Platform, Page 3-8).
3. Remove the gas bottles from the paver (only applies to pavers fitted with the
optional gas heating).Chapter 2 Screed Heating System (Option), Page 2-30
4. Dismantle any screed extensions to reach the specified transport width (refer
to the operating manual for your screed); raise and secure the screed in the
transport lock (Chapter 3 Screed Transport Lock, Page 3-36). Retract the
Variomatic screed to the basic width.
5. Remove all components from the paver which protrude beyond the basic width.
6. Switch off the engine, lock all compartments and switch off the power supply
with the battery master switch (Chapter 3 Switching the Power Supply ON and
OFF, Page 3-7).
7. Check all fluid levels so that they do not escape when the machine is tilted.
8. Remove all loose objects from the paver.
9. Lower the sun roof (Chapter 3 Raising and Lowering the Sun Roof, Page 3-9).
10. Use wheel chocks to secure the front and rear wheels of the transport vehicle.
11. Attach the crane slings to the hoisting points marked on the paver (illustration
refers).
3-63
Chapter 3
OPERATION
12. The load suspension point (Fz) must be brought to a position vertically above
the paver's centre of gravity (Fg).
The paver's centre of gravity (Fg) depends upon the type of screed fitted to the
machine.
Basically, the paver's centre of gravity is between the first and second track roller
in front of the crawler drive assembly.
13. Place dismantled screed extensions or similar heavy objects in the hopper to
balance the weight of the paver when hoisting. Ensure the items placed in the
hopper are safely secured against moving.
14. Cordon off the loading area and ensure no persons are in the danger zone.
15. Carefully hoist the paver with the crane and check the lashing points and
balance. Only hoist the paver onto the vehicle after checking that all crane
slings are correctly attached and the machine is not out of balance.
16. Position the paver on the vehicle so that it is exactly in the middle of the loading
bed.
17. Securely lash the machine as soon as it is on the loading vehicle. (refer to
Lashing the Machine on the Vehicle, page 3-66).
3-64
OPERATION
Chapter 3
3-65
Chapter 3
OPERATION
DANGER
Only use hoisting and lashing chains and slings which comply with all
prevailing regulations.
Strictly observe the following instructions to avoid serious personal
injury and damage to the machine when loading and transporting the
paver:
When choosing lashing chains and slings, take the weight of the paver (technical
data refers) and the paving screed (refer to the screed's operating manual) into
consideration.
Chains and slings must comply with all locally prevailing accident prevention
regulations and must have sufficient strength to take the weight of the machine.
Only fasten the lashing slings and chains to the lashing points provided on the paver.
Observe all locally prevailing laws, regulations and the traffic code when driving or
transporting the paver on public roads.
Illustration 40
1. Release and lower the screed from the transport locking device (Chapter 3
Screed Transport Lock, Page 3-36). During transport, the screed must be
completely lowered and resting on the bed of the transport vehicle.
2. Finally, securely lash the machine on the bed of the loading vehicle using
suitable chains and slings in compliance with your locally prevailing regulations
and use wheel chocks if necessary. Attach the chains and slings to the lashing
points marked on the paver.
3-66
CHAPTER 4 - MAINTENANCE
4-1
Chapter 4
MAINTENANCE
MAINTENANCE
Only use genuine spare parts to uphold warranty claims and to achieve a reliable machine
operation as well as an optimum paving output.
IMPORTANT INSTRUCTIONS
WARNING
The procedures for starting and stopping the paver as well as the instructions for
maintenance work described in the operating manual must be strictly observed when
performing any work which affects the operation, configuration and adjustments on
the paver and its safety devices as well as maintenance, servicing and repair work.
4-2
Only carry out maintenance and repair work after the paver has been parked on firm
and level ground and safely secured against unintentional movements.
Exercise extreme care to avoid accidents if lifting devices are attached to individual
parts and larger assembles for removing them from the machine. Only use lifting
devices which are in a perfect working condition and have the required lifting
capacity. Never work or stand below suspended loads.
Always use the correct tools and workshop appliances for maintenance and repair
work on the machine.
Always use suitable ladders or working platforms for assembly work on components
higher up on the machine. Never use components for climbing onto the machine.
All grip bars, steps, handrails, platforms, decks and ladders must be kept free from
mud, dirt, snow and ice.
Before carrying out any maintenance and repair work, clean the machine, especially
connections and threaded fastenings from oil, fuel and remnants of preservation
grease. Never use aggressive cleaning solvents. Always use non-fibrous cleaning
MAINTENANCE
Chapter 4
cloths.
Before cleaning the machine with water, steam jets (high pressure cleaners) or other
cleaning agents, close or seal with adhesive tape all doors, hatches and openings
which for safety or functional reasons must be protected against water, steam or
cleaning solvents. Exercise special care with electric motors and electronic
equipment.
Ensure that temperature feelers do not come into contact with hot cleaning solvents
when cleaning the machine.
Remove all covers and adhesive tape after cleaning the machine.
After cleaning the machine, check all lines for fuel, grease and hydraulic fluid for
leakage, loose connections, chafing and damage. Immediately repair or renew all
faulty parts.
Tighten all threaded connections previously loosened for maintenance and repair
work.
After completion of maintenance and repair work, replace and check all safety
devices previously removed.
Ensure that all consumables and spare parts have been correctly disposed of in
accordance with your locally prevailing environment regulations.
Avoid carrying out maintenance, cleaning and inspection work when the engine is
running.
Never refuel the machine if the engine is running, near naked flames and do not
smoke.
Do not alter the engine adjustments. The details on the engine manufacturer's
identification plate must correspond to the engine adjustments.
Always replace lost warning signs and symbols.The position and the part numbers
of the warning signs and symbols can be found in the spare parts list.
By using genuine spare parts, you will maintain the operating safety and optimum
machine performance guaranteed in the warranty conditions.
Switch off the power supply with the battery master switch before working on the
electrical system or carrying out any welding work on the machine (Chapter 3
Switching the Power Supply ON and OFF, Page 3-7).
4-3
Chapter 4
4-4
MAINTENANCE
Ensure the battery cover is removed when connecting jump starter cables and
battery chargers to the battery (avoid an accumulation of battery gasses). Battery
gasses can be ignited to an explosion by sparks.
The battery charger MUST be switched off when connecting it to the battery.
Only use genuine fuses with the specified amperage. Immediately switch off the
paver if problems occur in the electrical system.
Any work on the machine's electrical system and equipment may only be performed
by a trained assistant electrician or a similarly trained person whereby they are
supervised and controlled by a fully trained and qualified electrician. This work must
be carried out in accordance with your locally prevailing electro-technical regulations
and directives.
Before starting work, ensure the sub-system, is disconnected and at zero potential
and earthed or short circuited. Furthermore, all live parts and components must be
isolated.
The paver's electrical equipment must be checked and examined at regular intervals.
Faulty parts such as loose connections or charred wiring must be immediately
renewed.
Welding, torch cutting and grinding work may only be carried out on the paver after
express permission has been obtained because this work can cause explosions and
fires.
Before commencing any welding, torch cutting or grinding work, the paver and its
surrounding area must be cleaned and free from all dust and inflammable materials
and the working area must be adequately ventilated (danger of explosions - check
all wiring and hoses for leakage and visual damage). Any damage found must be
immediately repaired. Escaped oil is a fire risk and health hazard.
Hydraulic hoses must be regularly checked and immediately renewed if they are
found to be chafed, cracked, brittle, deformed or have visible bulges, leakages, loose
connections or any other damage which impairs their function or durability.
Never carry out any work on the hydraulic lines when the engine is running and the
system is under pressure. Hydraulic fluid is still under pressure even though the
engine has been switched off.
Before starting any repair work, all systems and the pressure lines to be removed
(hydraulic system, compressed air system) must be depressurised in accordance
with the instructions for the particular components.
Never commence any work on hydraulic hoses and connections until the pressure
has been properly relieved from the system.
MAINTENANCE
Chapter 4
Wait until the hydraulic fluid has cooled down before disconnecting any hydraulic
hoses. Hot hydraulic fluid will cause serious burns and scolding.
Do not use your hand to check for leakage in the hydraulic system. Use a piece of
cardboard and wear protective gloves and goggles.
Even a small amount of hydraulic fluid can cause serious injuries and fatal accidents.
Immediately remove hydraulic from your skin. Immediately go to a doctor if hydraulic
fluid gets into your eyes, you swallow or breath it.
Hydraulic lines must be correctly routed and properly connected. Ensure the
hydraulic connections are not swapped with each other. The connections, length and
quality of the hydraulic lines must comply with all technical requirements.
Strictly observe the product specific safety regulations when handling oil, grease and
other chemical substances.
Exercise special care when handling hot materials (danger of burning and scolding).
4-5
Chapter 4
MAINTENANCE
Levelling system
Battery
Alternator
Furthermore, the earth terminal on the welding appliance must be clamped in the immediate
vicinity of the part to be welded. The welding current must not pass through bearings.
Reconnect the above components in the opposite sequence on the completion of welding
work.
4-6
MAINTENANCE
Chapter 4
MAINTENANCE CHART
The maintenance chart contains the components which must be regularly serviced and their
maintenance intervals. All components listed under a maintenance interval should be regularly
serviced. These intervals are based on the average operating conditions and manufacturer's
recommendations. The maintenance intervals must be shortened if the machine is operated
under extremely difficult, dusty or humid conditions (more frequent maintenance is required).
In the following table, the maintenance intervals specified by the manufacturer may deviate
from those intervals specified by the engine manufacturer but must still be adhered to. When
performing the work for a maintenance interval, you must also perform the work for the previous intervals. For example, if you carry out a yearly maintenance, you must perform the work
for the yearly intervals and also for the half-yearly, quarterly, weekly and daily maintenance
intervals.
NOTICE
Please refer to the separate documentation for the maintenance work for
the screed and engine.
The maintenance work marked with an asterisk * must be carried out
together with the first service at 100 operating hours. Thereafter, the
specified maintenance intervals apply.
Further
Information
As required
Tighten threaded connections
410Page
414Page
330Page
Clean the filler neck sieve for the emulsion spraying system
226Page
4-7
Chapter 4
MAINTENANCE
Maintenance Work
Further
Information
410Page
332Page
429Page
Grease the auger drive case seal and all auger bearings
429Page
411Page
436Page
420Page
420Page
428Page
433Page
421Page ff
421Page ff
421Page ff
421Page ff
434Page
414Page
421Page
412Page
4-8
419Page
MAINTENANCE
Chapter 4
Maintenance Work
Further
Information
429Page ff
429Page ff
Engine handbook
Engine handbook
Engine handbook
415Page
Engine handbook
Engine handbook
Check the bolts on the hydraulic cylinders for tight fitting and wear
Change the filter cartridges for the levelling cylinders and augers
416Page
Change the filter cartridge for the travel drive and tamper drive
417Page
418Page
434Page
433Page
Engine handbook
436Page
418Page
4-9
Chapter 4
MAINTENANCE
MAINTENANCE WORK
CAUTION
The engine must be switched off when carrying out the following
maintenance work.
MACHINE (GENERAL)
Cleaning the Machine
When cleaning the machine and machine components with a hose or high pressure cleaner,
water and other impurities can penetrate bearings, seals and other components in the system.
NOTICE
When using high pressure cleaners, ensure that water or steam does not
penetrate electrical components and control systems.
Do not use any aggressive cleaning solvents which may cause damage
to painted surfaces.
Let the engine run warm after washing the machine. This will allow the
engine components and electrical connections to dry quicker.
Lubricate all grease nipples after cleaning the machine.
Before Cleaning
1. Correctly tighten all loose nuts and threaded connections found during daily
maintenance. (refer to Torques for threaded connections, page 8-2.)
2. Renew any loose self-locking nuts if necessary.
4-10
MAINTENANCE
Chapter 4
DIESEL ENGINE
NOTICE
Instructions for upkeep and maintenance procedures for the Diesel
engine as well as details of the required consumables are included in the
appended engine manufacturer's handbook.
Check the engine oil level
CAUTION
Wrong oil level. The wrong oil level will damage the engine. Switch off the
engine and weight for about 10 minutes for the oil to settle in the sump.
Illustration 6:
If the oil level is between max and min: the level is OK.
If the level is above max: Drain off oil to the correct level. (refer to Oil Change,
Diesel Engine, page 4-38)
If the level is below min: Add oil through the filler cap (2) to the correct level.
4-11
Chapter 4
MAINTENANCE
Illustration 7:
4-12
MAINTENANCE
Chapter 4
ELECTRICAL SYSTEM
WARNING
NOTICE
Information on battery upkeep and maintenance is contained in the
engine handbook.
The Diesel engine is equipped with a 28 V three-phase alternator. Due to the characteristics
of the three-phase alternator, special instructions for system with three-phase alternators must
be observed.
Observe the correct polarity when connecting the batteries otherwise the diodes will
be destroyed.
To determine whether a DC dynamo is supplying current, you can lightly touch the
earth. NEVER test a three-phase alternator in this way otherwise the semiconductors will be damaged.
The preexcitation of the three-phase alternator is effected by the battery via the
battery charging lamp (A5c, 27Page). Therefore, a faulty charging lamp must be
immediately renewed to ensure a correct excitation.
Illustration 8
4-13
Chapter 4
MAINTENANCE
4-14
MAINTENANCE
Chapter 4
HYDROSTATIC SYSTEM
Extreme cleanliness is a basic requirement for all maintenance and repair work on hydraulic
systems. Used oil, sand, dirt and metal chippings in hydraulic systems not only impair the
function and service life of the components, they also cause damage and eventually a complete breakdown of the system.
Regularly check the hydraulic system for leakage and tight fitting of all threaded connections.
CAUTION
When replacing hydraulic pumps and motors, the oil drain case must be filled with clean
hydraulic oil before putting them back into operation. Add oil through the drain case oil
connection (1).
Before putting the system back into operation, we recommend to flush the hydraulic lines; if
necessary, they must be dismantled .
A second possibility is to fit a high pressure filter with a filter mesh of 0.01 mm (10 um) into the
appropriate circuit instead of the hydro motor and filter the circuit for approx. 5 to 10 minutes
(check the filter's direction of flow).
4-15
Chapter 4
MAINTENANCE
Illustration 10
The filter cartridges on the high pressure filters for the levelling cylinders (1) and the
augers (2) must be changed for the first time at 125 operating hours and thereafter
every 1000 operating hours or at least once a year.
4-16
MAINTENANCE
Chapter 4
Feed Pressure Filter for the Travel Drive and Tamper Drive (only for VDT and VDT-V Screeds)
Illustration 11
The hydraulic oil is filtered by the feed pressure filters (3) installed on the pressure side of the
feed pumps. The feed pressure filters do not have a bypass which means that if the filter is
blocked, no unfiltered oil enters the closed circuit.
Instead of a bypass, the filters have integrated over pressure valves which open and allow the
hydraulic oil to flow back to the tank if the difference in pressure between filter inlet and filter
outlet is more than 5 bar.
With an increasing amount of dirt in the filter or with a too high oil viscosity at low temperatures,
the displacement of the variable pump in the main circuit will be delayed or there will be no
displacement at all. As a consequence: the paver's travel drive will lag or the paver will not
travel at all.
If this is due to cold oil, let the hydraulics run warm to reach normal operating temperature. If
this is due to a dirty filter, immediately change the filter cartridge.
Change the filter cartridge for the first time at 125 operating hours and thereafter every 1000
operating hours or at least once a year.
CAUTION
After every filter change, run the Diesel engine for approx. 5 minutes at
idling speed, i.e. max. 800 1/min to build up the feeding pressure.
4-17
Chapter 4
MAINTENANCE
Illustration 12
A vent filter is integrated in the filler cap for the hydraulic oil tank. The gauze must be cleaned
every 500 operating hours with compressed air; thereafter, moisten the gauze with a little
clean hydraulic oil.
4-18
MAINTENANCE
Chapter 4
Illustration 13
To ensure an adequate cooling, the hydraulic oil cooler and engine radiator (2) must be
cleaned every 250 operating hours. To do this, soak them with a cold cleaning solvent and
spray them with a strong jet of water; better still, use a steam pressure cleaner.
Access to the radiator is gained through the duct at the rear of the hopper (1).
Carry out the cleaning work as described in the engine manufacturer's handbook.
NOTICE
When operating under very dusty conditions, it may be necessary to
shorten the cleaning intervals if the hydraulic oil temperature or the
engine temperature unduly rises.
4-19
Chapter 4
MAINTENANCE
TRANSMISSION GEARS
Check the pump distributor gear
Illustration 14
Check the tubing, hoses and transmission gear daily for leakage.
Regularly check all threaded connections for tightness and visual damage.
Check the oil level and/or change the oil (refer to Chapter 4 Oil Change, Pump
Distributor Gear, Page 4-34).
Illustration 15
4-20
Regularly check all threaded connections for tightness and visual damage.
Check the oil level and/or change the oil (refer to Chapter 4 Oil Change,
Transmission Gears, Page 4-33).
MAINTENANCE
Chapter 4
checked for wear (e.g. connecting links and tooth flanks etc.),
When checking the drive chain tension, the connecting links, drag links and sprocket wheels
should also be checked for undue wear (damage to the tooth flanks) and renewed if
necessary.
4-21
Chapter 4
MAINTENANCE
Illustration 16
CAUTION
When checking or tensioning the auger drive chains, you should drain
the condense water out of the drive case at the same time.
A threaded drain plug (10 mm A/F) is located at the lowest position on the
auger drive case for draining off any water collected in the case to
prevent damage to the auger drive system. Replace and tighten the drain
plug (1 & 2) after draining the water.
V-belts
Tension and renew the V-belts according to the instructions in the engine handbook.
4-22
MAINTENANCE
Chapter 4
Drive chains
Illustration 17
Push the middle of the chain (2) with a screwdriver to check the tension.
The chain must be retensioned if you can depress it by more than 10 mm.
To do this, loosen the 4 screws (6) and the locking nut (7).
Turn the tensioning screw on the hydro motor clockwise until you can depress the
chain by approx. 5 mm. Then tighten the locking nut (7).
Remarks: The bearings will wear prematurely if there is too much tension on
the drive chain.
4-23
Chapter 4
MAINTENANCE
Illustration 18
Loosen the locking nuts (30 mm A/F), 2 locking per conveyor and tension the conveyor with
the 2 nuts (30 mm A/F) located on the front cross member on the paver's frame (1).
The conveyor must be equally tensioned so that both sides of the conveyor have the same
sag.
The sag should measure approx. 50 to 70 mm in a cold condition. After tensioning the
conveyor, retighten the locking nuts.
4-24
MAINTENANCE
Chapter 4
Illustration 19
Rotate the auger shaft to and fro and observe the tension on the drive chain. The
drive shaft on the hydraulic motor should not rotate when turning the auger shaft. The
tension on the auger drive chain is correct if there is approx. 5 [mm] of free play on
the circumference of the auger flight.
Tension the chain with the hex bolt (3) (24 mm A/F) until the above value of approx.
5 mm is reached.
4-25
Chapter 4
MAINTENANCE
Illustration 20
Press the drive chain with a screwdriver; the chain should only yield slightly, tension
the chain if it is too slack. .
4-26
Loosen the 4 bolts (19 mm A/F) and tension the chain with bolt (3/4) (19 mm A/F). .
Rotate the auger shaft to and fro and observe the drive chain tension, the drive shaft
on the hydraulic motor should not rotate; the tension on the auger drive chain is
correct if there is approx. 5 [mm] of free play on the circumference of the auger flight.
MAINTENANCE
Chapter 4
4-27
Chapter 4
MAINTENANCE
LUBRICATION PLAN
All lubrication instructions contained in this lubrication plan only refer to the basic paver.
Lubricating instructions for the paving screed are contained in the operating manual for the
screed.
Park the paver on level ground before checking the oil levels and changing the oil. Always
drain off the oil at operating temperature and catch it in a suitable container.
Observe meticulous cleanliness when greasing the machine. Thoroughly clean the grease
nipple before applying the grease gun.
Slip guides and spindles must be greased or oiled as required especially after cleaning the
paver with grease and bitumen dissolving agents. Use a commercially available multi-purpose
quality grease.
The paver's chain drives must be lubricated once a week. Lubricating work can be done with
an oil can or aerosol can. Apply the lubricant between the link plates of the inner and outer
links. For normal operating conditions, use a quality brand of oil with a viscosity of SAE oils.
Choose an oil to suit your average ambient temperature:
Table 21:
Temperature Range
SAE
Viscosity Classification
-5 C to +25 C
30
VG 100
+25 C to +45 C
40
VG 150
+45 C to +65 C
50
VG 220
Once a month clean the chain drives with an oil and grease removing solvent; thereafter oil
the chains. At the end of the paving season, thoroughly clean all chains and sprockets and
preserve them with a special chain grease.
Remarks: After lubricating, remove the grease gun nozzle from the grease
nipple by turning the gun clockwise at an angle of approx. 30. This will make
it easier to remove the grease gun without braking off the ball head on the
grease nipple.
Use extreme CAUTION when working in the vicinity of moving parts.
When paving bituminous materials, the conveyor and auger bearings must be immediately
lubricated at the end of paving work. To do this, run the conveyors and augers and apply
grease until it emerges from the cavities. Any paving material which may have penetrated the
seals will be forced out by the lubricant.
Grease points with daily intervals must be lubricated before washing the machine so that the
gaps in the bearings are closed with grease. Grease points with daily intervals must be
lubricated before washing the machine.
Do not direct the jet of water onto the bearings.
4-28
MAINTENANCE
Chapter 4
GREASE POINTS
The grease points 1 to 5 must be lubricated every 10 operating hours.
Lubricant:refer to Consumables, page 7-2
Illustration 22
4-29
Chapter 4
MAINTENANCE
Illustration 23
4-30
Chapter 4
MAINTENANCE
The grease points 6 and 7 must be lubricated every 500 operating hours.
Lubricant: refer to Consumables, page 7-2
Illustration 24
225/325
Chapter 4
MAINTENANCE
4-32
Disconnect the lubricating line (Fig. 1 & 2) and screw in a normal grease nipple (Fig.
3).
Apply grease with the grease gun (Fig. 4) until it emerges out of the cavities.
Finally, remove the grease nipple and reconnect the grease line (Fig. 1).
MAINTENANCE
Chapter 4
4-33
Chapter 4
MAINTENANCE
4-34
MAINTENANCE
Chapter 4
Use a non-fibrous clean cloth to wipe the dip stick dry and ten return it into the hole
in the housing.
Remove the dip stick once again and check the oil level.
The oil level is correct if it is between the MAX and MIN marks on the dip stick.
The oil level is too low if it is just above the MIN mark on the dip stick (the oil level
should never be below the MIN mark).
Draining the Oil: Unscrew and remove the filler plug with dip stick ( 11a) so that air enters the
gear and lets the oil trickle out. Then unscrew and remove the drain plug (11c on the LH side
of the paver) and catch the oil in a suitable container.
Filling the Oil: Fill 1.25 litres of transmission oil MB 90 through the filler plug (11a). Check the
oil level with the dip stick as previously described.
4-35
Chapter 4
MAINTENANCE
4-36
MAINTENANCE
Chapter 4
Quantity: 205 litres to fill to complete system; approx. 160 litres for an oil change
Quality: refer to Consumables, page 7-2
Table 29:
Temperature Range
SAE
below 0C
10 W
-10 C to +15 C
20W/20
0 C to +35 C
30
+25 C to +50 C
40
-20 C to +30 C
10W/40
Check the oil level: Sight glass on the hydraulic oil tank.
Remarks: If the paver has a Variomatic screed, completely retract the
screed to check the oil level.
Draining the Oil: Drain the oil at operating temperature. Flush the tank to remove any oil
sediment (1).
Catch the oil in a suitable container. Take the hose from the tool kit and connect it to the drain
valve on the bottom of the hydraulic tank. Tighten the threaded connection (12b) until the oil
trickles out of the hose.
Filling the Oil: Fill oil through the filler neck (12c) on the top of the oil tank.
After an oil change, let the Diesel engine run for approx. 5 minutes at idling speed (max. 800
1/min) to let any air escape from the hydraulic lines.
4-37
Chapter 4
MAINTENANCE
4-38
CHAPTER 5 - TROUBLE
SHOOTING
5-1
Chapter 5
TROUBLE SHOOTING
TROUBLE SHOOTING
WARNING
When trouble shooting, it is absolutely essential that you read and strictly
observe the safety instructions contained in Chapter 1 Safety, Page 12 of this manual.
Improper paver operation and maintenance are the most frequent causes of faults and
breakdowns. If a breakdown occurs, first read the operating manual and especially the chapter
on maintenance.
Notify your service technician or distributor if you cannot locate the cause of the problem or
required assistance when replacing faulty parts.
5-2
TROUBLE SHOOTING
Chapter 5
TROUBLE SHOOTING
Fault
Engine does not start
Possible Cause
Fault Clearance
Machine veers
sharply to the left or
right
Auxiliary control
No function has been
allocated to this key
K 29 , K 11 or K 10 faulty or
faulty current circuit
5-3
Chapter 5
TROUBLE SHOOTING
Fault
Machine does not
travel straight ahead
5-4
Possible Cause
Fault Clearance
Machine cannot be
steered
Speed cannot be
switched to transport
speed
"Turning-on-the-spot"
does not function
TROUBLE SHOOTING
Chapter 5
Fault
Possible Cause
Fault Clearance
Offset Adjustment:
With the offset adjustment, the
starting values are calibrated for
the hydraulic pumps on the
travel drive system. If a faulty
function occurs (e.g. sensor
error), the paver will start
moving slowly. In this case,
the offset adjustment procedure can be immediately
stopped by moving the drive
lever or pressing the emergency
STOP button. For this reason,
it is absolutely essential that
the operator remains on the
operator's platform during the
offset procedure (approx. 2 to
3 minutes for each side).
Change the electronics to the
programming mode (Move the
plug-in bridge from X1/115-X1/
116 to X1/116-X1/117).
Start the offset adjustment on
the LH side by moving the drive
lever forwards.
During the calibration, the LH
sensor will flash and will permanently illuminate when the calibration is finished.
Start the offset adjustment on
the RH side by moving the drive
lever backwards.
During the calibration, the RH
sensor will flash and will permanently illuminate when the calibration is finished.
Finalise the offset adjustment
procedure by moving the plug-in
bridge from X1/116-X1/117
back to X1/115-X1/116.
Now start the machine moving
in the paving speed stage.
Repeat the offset adjustment if
the machine starts with irregular
movements.
Contact your nearest service
technician if the fault cannot be
rectified after several attempts
at the offset adjustment procedure.
5-5
Chapter 5
TROUBLE SHOOTING
Table 1:
Pos.
Description
Function
Fuses
Relays
NOTICE
Replace a blown fuse with a fuse of the same amperage. If the fuse has
not blown, the fault may be in that particular circuit. Contact your service
technician or distributor if the fuse blows in the same circuit several
times without a recognisable cause.
5-6
TROUBLE SHOOTING
Chapter 5
CAUTION
It is only permitted to tow the paver with a tow bar at a slow towing speed
of approx. 10 m/min over a short distance to remove the machine from the
danger zone or tow it to a low bed loader.
Ensure there are no persons or objects in the danger zone. Observe your
locally prevailing laws, regulations and the traffic code when towing the
paver. There is a danger of crushing and serious personal injury when
preparing the paver for towing.
Ensure the crawler tracks do not skid. The paver can only be steered and
guided by the towing vehicle if the Diesel engine has broken down.
Before unhitching the tow bar, ensure it is not under tension and the
paver is secured against moving by applying the spring loaded brake or
by wheel chocks.
Due to the hydrostatic travel drive, it is not permitted to tow start the
Diesel engine if the electric starter has broken down. Any attempt to tow
start the Diesel will cause damage to the hydrostatic drive system.
5-7
Chapter 5
TROUBLE SHOOTING
(5) = Manometer
(6) = Brake
1. Connect the manometer to the test connection (1) on the RH drive motor.
2. Remove the brake connection (4) from the brake valve (2).
3. Close the brake valve (2).
4. Screw the brake connection (4) onto the valve unit (3); then close the brake
connection. When doing this, the lines must not run dry.
5. Connect the grease gun to the grease nipple on the valve unit (3).
6. Keep pressing the grease gun to pump grease into the line until the manometer
(5) shows a pressure of 30 bar. The spring loaded brake (6) is now released.
7. After towing the paver, return the brake system to its original condition.
5-8
TROUBLE SHOOTING
Chapter 5
The oil can flow freely by screwing in the adjusting screws (1) until they are flush with the lock
nuts on both tandem mounted drive pumps (2). The oil can then flow freely in the circuit.
1. Loosen the lock nuts on both adjusting screws (1).
2. Screw in the adjusting screws (1) until they are flush with the lock nuts.
3. Retighten the lock nuts.
4. Unscrew the adjusting screws to their original positions and secure them with
the lock nut as soon as the paver is ready for operation.
5-9
Chapter 5
TROUBLE SHOOTING
The augers can be manually controlled using the two levers (1) if a breakdown or jamming
occurs in the hydraulics. Using this manual auger control feature you can remove paving
material from the auger channel before towing the paver.
5-10
6-1
Chapter 6
TECHNICAL DATA
Technical Data
TITAN 225
GENERAL DATA
Titan 225
Engine
Fuel tank
236 litres
Paving output
Paving thickness
Up to 300mm
Travel drive
Paving speed
0-16 m/min
Transport speed
0-3.6 km/h
Crawler unit
Crawler tracks with rubber track pads, 9 track rollers, ground contact area approx. 2900 x 305 mm
Hinge mounted road scrapers
Hopper
Conveyor system
6-2
TECHNICAL DATA
Hydraulics
Chapter 6
Electrics
Weight
Railings with seat console and sun roof, crosssliding control panel, 2 deluxe seats, tool kit and
continuous towing arms
Options
Side curtains for sun roof, orange warning beacon, cab with heating, voltage regulator for 12 V
levelling system, 2 additional rear working lights,
56 mm spacer blocks for the towing arms, screed
anti-climbing lock, screed assist, central lubrication system, emulsion spraying system for cleaning, Pave Control, analogue or digital levelling
system, multi-foot levelling beam, levelling tube,
spray gun for cleaning, ThermoControl for
screed heating, Diesel heating system for Vario
screeds
6-3
Chapter 6
TECHNICAL DATA
Titan 225
Noise Level
The following sound levels were determined according to the provisions of 1.7.4 (f), Annex
1 of the EU Directives for Machinery 98/37/EC:
Equivalent continuous A weighted sound power level on the operator's platform: 90 dB(A)
Guaranteed maximum A weighted sound power level on the machine: Lw = 110 dB(A)
These measurements were made according to ISO 6394, ISO 6396 and ISO 6395 at the
nominal speed specified by the manufacturer. The noise values may vary depending on
the type of screed fitted to the paver, the paving conditions and the paving material.
Therefore, the actual values reached during paving work may deviate from the values
specified.
Stress on the Operator caused by Vibrations
The following values were determined according to the provisions 3.6.3 (a), Annex 1 of the
EU Directives for Machinery 98/37/EC:
Entire body vibrations on the operator's platform: The weighted effective value of
accelerations to which the body is exposed does not exceed 2.5 m/s.
The measurements were made according to ISO 5349 and ISO 2631 with the machine
operating at the maximum vibration amplitude and maximum frequency.
6-4
TECHNICAL DATA
Chapter 6
DIMENSIONS
Illustration 7: Dimensions Titan 225
6-5
Chapter 6
TECHNICAL DATA
TITAN 325
GENERAL DATA
Titan 325
Engine
Fuel tank
236 litres
Paving output
Paving thickness
Up to 300mm
Travel drive
Paving speed
0-16 m/min
Transport speed
0-3.6 km/h
Crawler Unit
Crawler tracks with rubber track pads, 9 track rollers, ground contact area approx. 2900 x mm
Hinge mounted road scrapers
Hopper
Conveyor system
6-6
TECHNICAL DATA
Hydraulics
Chapter 6
Electrics
Weight
Options
Side curtains for sun roof, orange warning beacon, cab with heating, voltage regulator for 12 V
levelling system, 2 additional rear working lights,
56 mm spacer blocks for the towing arms, screed
anti-climbing lock, screed assist, central lubrication system, emulsion spraying system for cleaning, Pave Control, analogue or digital levelling
system, multi-foot levelling beam, levelling tube,
spray gun for cleaning, ThermoControl for
screed heating, Diesel heating system for Vario
screeds
6-7
Chapter 6
TECHNICAL DATA
Titan 325
Noise Level
The following sound levels were determined according to the provisions of 1.7.4 (f), Annex
1 of the EU Directives for Machinery 98/37/EC:
Equivalent continuous A weighted sound power level on the operator's platform: 85 dB(A)
Guaranteed maximum A weighted sound power level on the machine: Lw = 106 dB(A)
These measurements were made according to ISO 6394, ISO 6396 and ISO 6395
at the nominal speed specified by the manufacturer. The noise values may vary depending
on the type of screed fitted to the paver, the paving conditions and the paving material.
Therefore, the actual values reached during paving work may deviate from the values
specified.
Stress on the Operator caused by Vibrations
The following values were determined according to the provisions 3.6.3 (a), Annex 1 of the
EU Directives for Machinery 98/37/EC:
Entire body vibrations on the operator's platform: The weighted effective value of
accelerations to which the body is exposed does not exceed 2.5 m/s.
The measurements were made according to ISO 5349 and ISO 2631 with the machine
operating at the maximum vibration amplitude and maximum frequency.
6-8
TECHNICAL DATA
Chapter 6
DIMENSIONS
Illustration 8: Dimensions Titan 325
6-9
Chapter 6
6-10
TECHNICAL DATA
CHAPTER 7 - CONSUMABLES
7-1
Chapter 7
CONSUMABLES
Consumables
Lubrication is a major element of preventive maintenance and has a significant effect on the
working life of the paver. Regularly lubricating moving parts will reduce the possibility of a
breakdown cause by a failure of mechanical components. We recommend the use of
genuine lubricants to achieve an optimum working life and performance of the paver.
Different lubricants are required to lubricate the paver and its integrated assemblies. This
chapter includes a table of assemblies to be lubricated and the lubricant required.
If not otherwise specified, the oil levels must be checked as follows: Park the machine on level
ground and check the level when the oil is cold.
The oil must reach the lower edge of the filling hole on oil check points with a threaded oil level
plug.
If not otherwise specified, the grease nipples are designed according to SAE-STANDARDS.
Lubricate open grease nipples until grease emerges out of the nipple.
Applying excessive lubricant to the grease nipple will not damage the grease nipple or its
assembly. Insufficient lubricant will, however, shorten the component's working life.
If not otherwise specified, lubricate all components without grease nipples (rods, bolts and
levers etc.) once a week with oil. A thin film of engine oil will achieve the required lubrication
and avoid rust. An anti-seizing solvent can be used if rust or corrosion has formed. Otherwise
the component must be cleaned before lubricating.
Worn or damaged grease nipples must be replaced if the grease gun cannot be connected or
the ball in the nipple has jammed.
In addition to the regular lubricating intervals, carry out other inspection and maintenance work
at the same time. This will avoid more serious damage occurring on the assemblies.
1. Before starting maintenance work, clean all threaded connections, caps and
plugs etc with a non-flammable and non-toxic cleaning solvent so that dirt
cannot penetrate the system during work.
2. Drain off all oils at operating temperature.
3. When carrying out lubricating work at the prescribed intervals, check and
ensure that all nuts, bolts and screws are correctly tightened.
4. Make a random inspection of threaded connections and nuts and check
whether they are tightened to the correct torque. If any loose connections are
found, then check and tighten all threaded connections, nuts and bolts.
5. If damage is found during maintenance work, then the machine must be shut
down until the faults are rectified. Notify your local distributor if necessary.
7-2
CONSUMABLES
Chapter 7
WARNING
Table 1:
Description
Application
Quantity
Specification
Diesel engine
20.5 litres
Hydraulic oil
hydraulic system
160 litres
Hydraulic oil
tensioning cylinders
2 x 0.5 litres
Gear oil
transmission gears
4 litres
Gear oil
pump distributor
gear
1.5 litres
Grease
vibrator bearings,
tampers, auger
bearings, conveyor
bearings and other
grease points
As required
Diesel fuel
As required
Diesel engine
(radiator)
17 litres
Engine oil
Engine coolant
NOTICE
All quantities are reference values which may vary within a series of
machines. After changing or topping up fluids, check the fluid level and
correct it if necessary.
Contact your nearest distributor or the manufacturer directly if your
machine is filled with biodegradable fluids or you wish to change to such
fluids.
7-3
Chapter 7
7-4
CONSUMABLES
8-1
Chapter 8
TORQUE
Bolt Size
8-2
lbs.-ft.
Nm
M6 x 1.0
12
M8 x 1.25
21
28
M10 x 1.5
45
61
M12 x 1.75
79
105
M14 x 2.0
125
170
M16 x 2.0
195
265
M20 x 2.5
380
515
M24 x 3.0
660
895
M30 x 3.5
1310
1780
M36 x 4.0
2290
3100
GLOSSARY OF TERMS
Glossary of Terms
Alphabetical Index
3-61
B
batteries. . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
charging ...............................................4-14
greasing the terminals .........................4-14
master switch ......................................2-33
battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
C
Central . . . . . . . . . . . . . . . . . . . . . 2-24, 4-32
Check the engine oil level . . . . . . . . . . . 4-11
Clean
hydraulic oil cooler and radiator ..........4-19
vent filter ..............................................4-18
clean . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Cleaning the Machine . . . . . . . . . . . . . . 4-10
Commissioning the Paver
check .....................................................3-6
Consumables . . . . . . . . . . . . . . . . . . . . . 7-2
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Control Column, Cross Sliding . . . . . . . 3-16
Control panels
external ................................................2-20
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Conveying the mix
to one side ...........................................3-59
Conveyors
operation ................................... 2-12, 2-17
tensioning ............................................4-24
conveyors . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Corrosion protection . . . . . . . . . . . . . . . . 1-8
Crawler . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
II
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Diesel engine
Oil change ........................................... 4-38
Dimensions
Titan 225 ............................................... 6-5
Titan 325 ............................................... 6-9
direction . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Direction Indicator . . . . . . . . . . . . . . . . . 3-51
Distributor . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Distributor augers
Auger height........................................ 3-42
extensions ........................................... 3-46
Filter .................................................... 4-16
Mix flow control ................................... 3-49
with centre drive.................................. 4-25
with outer drives .................................. 4-26
Drive chains . . . . . . . . . . . . . . . . . . . . . . 4-21
Drive lever . . . . . . . . . . . . . . . . . . . . . . . 2-14
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
E
Electrical power supply
ON / OFF .............................................. 3-7
Electrical system
Maintenance ....................................... 4-13
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Electronic levelling system . . . . . . . . . . 2-32
Emergency Control . . . . . . . . . . . . . . . . 3-28
Emergency operation . . . . . . . . . 2-38, 3-28
Emergency STOP
indicated on the control panel .............. 2-8
release ................................................ 2-10
switch .................................................. 2-10
Emission . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Emulsion . . . . . . . . . . . . . . . . . . . . 2-3, 2-26
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
jump starting ....................................... 3-21
Engine coolant level . . . . . . . . . . . . . . . . 2-8
Engine oil pressure . . . . . . . . . . . . . . . . . 2-8
Engine oil temperature . . . . . . . . . . . . . . 2-7
Engine speed . . . . . . . . . . . . . . . . . . . . . 2-19
Engine, start. . . . . . . . . . . . . . . . . . . . . . 2-14
Important instructions ......................... 3-19
with the starter batteries ..................... 3-20
Engine, stop . . . . . . . . . . . . . . . . . 2-14, 3-23
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Glossary of Terms
External . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
External control panels . . . . . . . . . . . . . 2-20
F
Feed pressure filter for travel drive and
tamper drive . . . . . . . . . . . . . . . . . . . . . 4-17
Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
first aid box
compartment ............................... 2-3, 2-22
safekeeping ...........................................0-4
First Oil Change . . . . . . . . . . . . . . . . . . . 4-6
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Front . . . . . . . . . . . . . . . . . . . . . . . 2-3, 3-34
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Tank ............................................. 2-3, 2-23
Fuel filter
draining off the condensed water ........4-12
Fuel level
indicated on the control panel ...............2-7
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Fuses . . . . . . . . . . . . . . . . . . . 2-35, 2-38, 5-6
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Hydraulic drive motors, free running . . . . 5-9
Hydraulic oil
temperature........................................... 2-8
hydraulic system
Oil change ........................................... 4-36
Hydrostatic System . . . . . . . . . . . . . . . . 4-15
I
Identification Plate
Engine ................................................... 0-4
Machine ................................................ 0-3
ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Ignition switch . . . . . . . . . . . . . . . . . . . . 2-14
Important information
general .................................................. 1-3
Important instructions
Maintenance ......................................... 4-2
Operation .............................................. 3-3
Instruments . . . . . . . . . . . . . . . . . . . . . . . 2-2
L
G
gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Gas bottle
connection ...........................................2-31
support...................................................2-3
tensioning belt .....................................2-31
Gas heating . . . . . . . . . . . . . . . . . . . . . . 2-30
hose routing .........................................1-11
precautions ..........................................1-10
Precautions for gas leakage ...............1-13
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
General Data
Titan 225 ...............................................6-2
Titan 325 ...............................................6-6
Grease. . . . . . . . . . . . . . . . . . . . . . 1-8, 4-29
H
Hazardous goods
handling ......................................... 1-8, 4-6
Hazards
special ...................................................1-8
Hopper. . . . . . . . . . . . . . . . . . . . . . 2-3, 3-36
Hopper wings . . . . . . . . . . . . . . . . . . . . 2-13
horn . . . . . . . . . . . . . . . . . . . . . . . 2-13, 2-21
hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Lashing . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Lashing the Machine on the Vehicle . . . 3-66
Levelling Cylinders
Filter .................................................... 4-16
Levelling System . . . . . . . . . . . . . 2-32, 3-51
Levelling system . . . . . . . . . . . . . . . . . . 2-18
List of Fuel Oils and Lubricants . . . . . . . . 7-3
Live electric cables
procedure when touching the cables . 1-14
Loading
by crane .............................................. 3-62
on a vehicle with ramps ...................... 3-65
Lubricant list. . . . . . . . . . . . . . . . . . . . . . . 7-3
lubricating . . . . . . . . . . . . . . . . . . . . . . . 3-32
Lubrication . . . . . . . . . . . . . . . . . . . . . . . 4-28
M
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
MAINTENANCE . . . . . . . . . . . . . . . . . . . 4-2
Maintenance
before starting ....................................... 4-5
chart ...................................................... 4-7
Electrical system ................................. 4-13
work..................................................... 4-10
maintenance
First Oil Change .................................... 4-6
III
Glossary of Terms
Manually releasing the parking brake . . . 5-8
Manually removing paving material . . . 5-10
master switch . . . . . . . . . . . . . . . . . . . . 2-33
Mat . . . . . . . . . . . . . . . . . . . . . . . . 2-3, 2-25
Mat thickness
adjusting ..............................................3-53
adjustment ................................. 2-20, 2-21
Mat thickness is not correct . . . . . . . . . 3-58
Material . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Mix flow
Augers .................................................3-49
Conveyors ...........................................3-50
Moba controller . . . . . . . . . . . . . . . . . . . 2-32
N
Noise and Vibration Values
Titan 225 ...............................................6-4
Titan 325 ...............................................6-8
O
Oil change
Diesel engine.......................................4-38
hydraulic system .................................4-36
Pump distributor gear ..........................4-34
transmission gears ..............................4-33
on-the-spot . . . . . . . . . . . . . . . . . . . . . . 3-27
Operating
in auxiliary control ...............................3-28
Operating hour meter . . . . . . . . . . . . . . . 2-8
Operating Manual
safekeeping ...........................................0-4
Operating Mode Automatic
paving ..................................................3-57
setting ..................................................3-52
Operation. . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Important instructions ............................3-3
Operator . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operator's Platform . . . . . . . . . . . . . . . . . 2-4
extending / retracting...........................3-14
setting up ...............................................3-8
Operator's Seat
deluxe .......................................... 2-6, 3-18
Standard ...................................... 2-5, 3-17
ordering . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
IV
P
Panel, control . . . . . . . . . . . . . . . . . . . . . . 2-7
Paver
lubricating............................................ 3-32
refuelling ............................................. 3-30
securing .............................................. 3-66
setting up ............................................ 3-29
Towing the paver .................................. 5-7
Paving . . . . . . . . . . . . . . . . . . . . . . 2-3, 3-52
in contaminated areas .......................... 3-4
in the vicinity of overhead electric cables ...
3-4
in the vicinity of railway lines ................ 3-4
in tunnels ............................................... 3-4
mix segregation .................................. 3-58
on bridges ............................................. 3-5
on slopes ............................................... 3-5
Paving mix
conveyed too slow .............................. 3-60
to one side .......................................... 3-59
Paving screed
extend/retract (Warning light) ............. 2-21
floating mode ...................................... 3-54
operation ....................................2-21, 3-39
screed spacer blocks .......................... 3-42
secure ................................................. 3-36
Tensioning Device .............................. 3-40
transport lock ...................................... 3-36
Personnel responsibilities . . . . . . . . . . . . 1-7
Platform
Control panel......................................... 2-7
operator's .............................................. 2-4
Power supply
ON / OFF .....................................2-33, 3-7
Preservation. . . . . . . . . . . . . . . . . . . . . . 4-27
Pressure . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Pump distributor gear . . . . . . . . . . . . . . 4-20
Oil change ........................................... 4-34
R
Raising and Lowering the Sun Roof . . . . 3-9
Rapid lubrication . . . . . . . . . . . . . . . . . . 2-10
Receiving the machine, procedure . . . . . 0-3
refuelling . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Removing . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Removing paving material from the auger
channel . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Glossary of Terms
Responsibilities
personnel ...............................................1-7
user / contractor ....................................1-5
Road . . . . . . . . . . . . . . . . . . . . . . . 2-3, 3-35
Rotary sensor . . . . . . . . . . . . . . . . . . . . 2-13
S
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety instructions
application specific ................................3-4
Safety precautions
when gas escapes ..............................1-13
when the machine touches live cables1-14
Schematic . . . . . . . . . . . . . . . . . . . . . . . 1-12
Screed . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
screed . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Screed / Floating mode . . . . . . . . . . . . . 2-16
Screed anti-climbing lock . . . . . . . . . . . 2-16
Screed assist . . . . . . . . . . . . . . . . . . . . . 2-15
setting the pressure.............................3-60
Screed control . . . . . . . . . . . . . . . . . . . . 2-16
Screed heating . . . . . . . . . . . . . . . . . . . 2-30
Screed raise and lower . . . . . . . . . . . . . 2-17
Screed spacer blocks . . . . . . . . . . . . . . 3-42
Seat Console, Extending and Retracting3-15
Sockets . . . . . . . . . . . 2-35, 2-36, 2-37, 2-40
Speed potentiometer. . . . . . . . . . . . . . . 2-10
Speed stage . . . . . . . . . . . . . . . . . . . . . 2-11
Spring loaded brake
indicated on the control panel ...............2-9
Starting . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Steering potentiometer . . . . . . . . . . . . . 2-15
STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
STOP material flow . . . . . . . . . . . . . . . . 2-21
Stopping . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Storage . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Sun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Switch Cabinet
operator's platform ..............................2-38
paver's rear wall ..................................2-39
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Tow point . . . . . . . . . . . . . . . . . . . 2-12, 2-18
Tow point sinks down . . . . . . . . . . . . . . 3-59
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Towing the paver . . . . . . . . . . . . . . . . . . . 5-7
Transmission gear . . . . . . . . . . . . . . . . . 4-20
Transmission gears
oil change............................................ 4-33
transport lock . . . . . . . . . . . . . . . . . . . . . 3-36
Trouble . . . . . . . . . . . . . . . . . . . . . . . 5-2, 5-3
Turning . . . . . . . . . . . . . . . . . . . . . 2-11, 3-27
U
Unintended Use . . . . . . . . . . . . . . . . . . . . 1-4
User / contractor responsibilities . . . . . . . 1-5
Using the machine for its intended use. . 1-4
V
V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Vibrators . . . . . . . . . . . . . . . . . . . . 2-9, 2-27
W
Warning beacon . . . . . . . . . . . . . . . . . . 2-34
Warning Horn. . . . . . . . . . . . . . . . 2-13, 2-21
Welding work on the paver
Important instructions ........................... 4-6
Windscreen . . . . . . . . . . . . . . . . . . . . . . 3-13
Working . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
X
Xenon. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
T
Table of torques . . . . . . . . . . . . . . . . . . . 8-2
Tampers . . . . . . . . . . . . . . . . . . . . 2-9, 2-27
Technical Data . . . . . . . . . . . . . . . . . . . . 6-2
Threaded connections . . . . . . . . . . . . . . 8-2
tighten ..................................................4-10
Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Glossary of Terms
VI
The warranty statement is provided within the manual kit shipped with the machine.
English
CST