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Big-Ski
(Volvo / ABG)
Assembly Manual
21A1004969
The text and graphic sections in this operating manual were prepared with particular care. Nevertheless, no liability can
be assumed, however, for any possible mistakes and their consequences. Please notify your authorised distributor of any
comments regarding the design and any faults. We will be only too glad to pick up on and implement sensible ideas and
suggestions for improvement.
Many companies, names and data used in the examples are, unless otherwise stated, fictitious. Some company and
brand names as well as product designations are subject to protection under brand, patent or trademark laws.
All rights reserved. No part of these documents may be reproduced or transmitted for any purposes, regardless of how
and with what means this happens, without the express written consent of the manufacturer.
Version: 5.2007
Volvo Construction Equipment
ABG ALLGEMEINE BAUMASCHINEN-GESELLSCHAFT mbH
Kuhbrckenstr. 18
D - 31785 Hameln
Table of contents
1. Foreword ............................................................................................................. 4
2. Notes on safety and work .................................................................................. 5
3. General information on the assembly instructions ......................................... 6
4. Scope of delivery................................................................................................ 6
5. List of the individual mechanical components ................................................ 7
6. Mechanics ........................................................................................................... 9
6.1 Attachment of the mechanics.......................................................................... 10
6.1.1 Assembly "Towing arm support"...................................................................................... 11
6.1.2 Assembly of the "swing arms" ......................................................................................... 12
6.1.3 Assembly of the "middle bracket" .................................................................................... 13
6.1.4 Assembly of the "module elements" ................................................................................ 15
6.1.5 Assembly of the "sensor brackets" .................................................................................. 16
-3-
1. Foreword
This manual contains important information and notes on the assembly of the BigSki mechanics.
Therefore, read the entire manual through carefully.
If questions arise which cannot be clarified using this assembly manual or the operating manual of the relevant MOBA-matic system, please contact your supplier.
Pictograms and symbols
The following pictograms and symbols are used in this manual:
ATTENTION!
IMPORTANT!
The warning triangle with an exclamation mark identifies all sources of danger which, in the event of incorrect procedure, represent a risk to the health of the
operating staff.
This reference identifies all sources of danger which,
in the event of incorrect procedure, may result in damage or malfunctioning of the machine.
Special notes are marked bold.
-4-
ATTENTION!
Always switch the MOBA-matic system into manual mode before you leave
the machine or when the machine is at a standstill.
Never perform work on the sensors as long as the system is in the automatic
mode.
If safety-relevant parts have to be dismantled for assembly of the system
components, they must definitely be installed again before initial commissioning.
Make sure that the screed is resting firmly on the ground before you perform
any work on the system.
Observe the safety notes of the machine manufacturer.
For welding
ATTENTION!
Never look unprotected into the arc.
IMPORTANT!
Before welding, disconnect at least the negative pole of the machine battery
and, dismantle, as far as possible, all electronic modules or interrupt their
power supply. Electric arc welding generates very high currents which may
destroy the machine electronics.
Position the negative pole of the welding machine in the direct vicinity of the
location where welding is to take place.
Remove any paint from the intended attachment point and the bracket to be
welded on. Prime and paint the weld after work.
Protect inflammable parts from flying sparks.
-5-
For assembly
IMPORTANT! When assembling the Big-Ski, it is imperative to ensure that neither the towing arm nor the screed structure are impaired in their freedom of
movement by the attachments!
In other words, manoeuvrability must be guaranteed in the entire working area.
Example:
4. Scope of delivery
The scope of delivery may differ depending on the length of the modular Big-Ski ordered. However, it always comprises all the mechanical system components as well
as the screws required for attachment for the respective expansion version.
The electric components and the appropriate cables are not included in the scope of
delivery.
-6-
7a
1
10
6
3
4
Pos.
Komponente
components
Bezeichnung
designation
Anmerkung
annotation
Mittelelement
Middle bracket
L = 2500 mm
ohne without 2 x 01-17-02806
Modulelement
Module element
L = 2100 mm
ohne without 1 x 01-01-00631
Sensorhalter, erweiterbar
Sensor bracket, extensible
L = 1080 mm
ohne without 2 x 01-17-02805
1 x 01-17-02806
Sensorausleger
Sensorboom, extension arm
Schiebehalter fr Sensorhalter
Sliding bracket, for sensor bra-
ohne without
2 x 01-17-02806
Sensorhalter
Sensor bracket
L = 1000 mm
ohne without
2 x 01-17-02805
ckets
7
Schwenkarm
Swing arm
7a
L = 1500 mm
L = 800 mm H = 420 mm
ohne without
4 x 01-01-00553
L = 800 mm H = 1000 mm
ohne without
4 x 01-01-00553
Fixierring, fr Sensorhalter
Clamp collar, for sensor brackets
45mm
ohne without 2 x 01-17-02806
Fixierring, fr Schwenkarm
Clamp collar, for swing arm
50mm
ohne without 2 x 01-17-02806
10
Halteplatte, fr Verteilerbox
mounting plate, for junctionbox
11
12
13
Kreuzgriffschrauben
Star knob screw
Schraube fr Verteilerbox
Screw for junctionbox
-7-
M8-20
M10-30
M6x12
Pos.
Komponente
components
Bezeichnung
designation
Anmerkung
annotation
14
Schraube fr Schwingarm
Screw for swing arm
M16x55
15
Schraube fr Modulelement
Screw for module elelement
M10x70
Klemmkonsole, vorne
18
zur Schwingarmbefestigung am
Zugarm
L = 350 mm
Klemmkonsole, hinten
19
zur Schwingarmbefestigung am
Zugarm
-8-
L = 500 mm
6. Mechanics
In creating the Big-Ski system the design of the mechanics assumed crucial importance.
The support for the sensors was to be designed to be very stable owing to the sometimes considerable length and screwed tight to the tool support. It is also advantageous to produce the structure in several sections in order to facilitate transport
and assembly. These aspects were taken into account, resulting in a design which
can be assembled and dismantled in a quick and uncomplicated manner.
In terms of design, the long beam was divided into small parts which can be modularly adapted to each other, i.e. different lengths can be achieved depending on the
combination of the attachments.
For example, with the combination 1 middle bracket and 2 module elements, a Ski
total length of max. approx. 9.20 m can be achieved together with the sensor
booms.
With the combination 1 middle bracket and 4 module elements a Ski total length of
max. approx. 13.50 m can be achieved together with the sensor booms.
The following describes the assembly of the long version as the shorter version is
achieved simply by leaving out two module elements.
Furthermore, it has proved practical if the alignment of the individual sensors can be
moved over the reference using the special sensor booms at the front and rear (in
practice Sonic-Ski is quite frequently positioned in front of and behind the machine
in order to ensure reliable scanning of the reference in curves).
X1
X2
The distances between the sensors are ideally the same (X1 = X2).
The middle sensor is attached at the usual single sensor position and so, when required, work can be performed with only one sensor simply by turning the switch on
the MOBA-matic (e.g. at the start of paving, road junctions etc.)
The mechanics can be mounted, depending on the application, at the side of the
screed or else above the screed. This depends on the paving width required in each
case.
The procedure for assembling the Big-Ski is identical in both cases.
-9-
To ensure that the Big-Ski can be operated as parallel as possible to the subsoil during paving, it has to be attached in line with the subsequent paving conditions.
For this purpose, the screed should be deposited according to the desired layer
thickness and the towing point set accordingly.
-10-
-11-
-12-
-13-
After the first part of the beam has been assembled, it is then aligned:
The middle bracket is now aligned horizontally using the clamp collars on the
swing arms and, if necessary, also with the clamp collars on the towing arm attachments.
Then the middle bracket is aligned parallel to the paver by turning the swing
arms.
-14-
To assemble the other module elements, simply insert the elements with
the hook.
-15-
-16-
"Extendable sensor brackets" are mounted on the two outer positions whereas one
normal sensor bracket is positioned in the middle.
A so-called "sensor boom" is then inserted from the outside into the two
outer "extendable sensor brackets".
All parts are to be secured after assembly using the M10 star knob screws.
If there is not enough space to push in the sensor brackets from below, then
simply raise the screed slightly using the transport cylinders. After assembly
of the sensor brackets, it is imperative to firmly deposit the screed again to
avert the risk of accidents.
- 17 -
The mechanical set-up is completed with the assembly of the sensor booms.
- 18 -
3 CAN-Sonic-Ski sensors,
1 junction box,
1 MOBA-matic,
1 (front)
2 (middle)
3 (rear)
To ensure that this is always the same on both sides, care must be taken during assembly of the junction box to ensure that the side input connector for connecting the
MOBA-matic is always pointing in the direction of travel (forwards).
Only in this way can it be guaranteed that the sensor messages displayed by the
MOBA-matic actually coincide with the sensor position.
- 19 -
During assembly of the Big-Ski, pay attention to the right-hand machine side:
In order to satisfy the requirement that the input connector is always pointing
in the direction of travel, the sliding bracket on which the junction box is to be
mounted must be pushed onto the Big-Ski from the inside to the outside.
- 20 -
If one sensor boom is swung to the side, care must be taken to ensure that
the sensor mounted is subsequently
aligned again in the direction of travel.
- 22 -
The text and graphics of this manual have been elaborated with the greatest possible care. However, we may not be held
liable for possible errors and failure effects.
Should you wish to make suggestions regarding the arrangement of this manual or point out possible errors, please contact your local
dealer. We will gladly take up any of your ingenious ideas and suggestions.
Some company and label names are subject to label-, patent- or trade-mark protection.
All rights reserved. This document must not be duplicated or transferred for any purpose whatsoever without MOBAs
written consent, irrespective of the way or the means which are used.
Date: 03.2005
Volvo Construction Equipment
ABG ALLGEMEINE BAUMASCHINEN-GESELLSCHAFT mbH
Kuhbrckenstr. 18
D - 31785 Hameln
Table of contents
3. Technical data.............................................................................................................. 17
-3-
1. General information
This operating instruction is not an instruction for the complete system.
It was created as a supplement to the operating instructions of the MOBA-matic
version 3.26.
So a system instruction for the Big-Ski consists of the operating instructions of the
MOBA-matic version 3.26 and this supplement.
-4-
2. The Big-Ski
2.1 Description
For the Big-Ski, the principle of averaging as known from the Sonic-Ski sensor
is adapted. For this purpose three Sonic-Ski sensors (CAN version!) are distributed
all over the machine length - or even projecting above it using the appropriate
mechanical aids.
In some exceptional cases, averaging can also be done with only two sensors
(Sonic-Ski at the front and the back side).
Due to this, even extensive unevenness or waves in the longitudinal direction of
the ground can be levelled out.
Big-Ski
-5-
X1
X2
-6-
Designation
Annotation
BIG-SKI
junctionbox to connect up to 3
Sonic-Ski, CAN
CAN
Y-Kabel
to connect Sonic-Ski, CAN or BigSki junctionbox to MOBA-matic
PWM
10pol/10pin/7pol
Baj.
6m
2 x 120
CAN
Coil cable,
to connect CAN-controller/sensors/
junction box to a hard wired CANBUS
7pol Baj./7pin
Baj.
6m
7pol Baj./7pin
Baj.
12m
BIG-SKI JUNCTION-BOX
Connection of the Big-Ski to the digital controller must be done by a special
Big-Ski junction box with appropriately coded connector plugs.
Y-CABLE
The y-cable serves as an adapter between 10pole connector (incl. CAN lines at
digital controller) and 7pole connector (CAN-connection to junction box or SonicSki).
SONIC-SKI-SENSOR (CAN)
The system can be operate with 1 up to 3 Sonic-Ski sensors. For the system only
Sonic-Ski with CAN-interface are usable. To prevent confusions between the SonicSki with PWM-interface and the Sonic-Ski CAN, both types have been fitted with
different attachment plugs. Thats the reason why a specific connecting cable is
needed for the CAN-Ski.
COIL-CABLE (for CAN-connection)
Generally applies: A 7pin connection with bayonet fixing always represents a CANconnection. The needed length (6m or 12m extended length) depends on the
mounting position of each Sonic-Ski-sensor.
-7-
-8-
-9-
or
-10-
2.4 Set-up
With the Big-Ski, only ground sensing is possible.
(if more than one Ski is connected to the junction box)
Therefore, all Sonic-Skis have to work longitudinally to the direction
of travel in order to obtain optimal results.
When working with the Big-Ski, the optimal working range of the
Sonic-Ski has to be considered as well.
Each of the Sonic-Ski sensors used has to be positioned in a
distance of 30 cm to 40 cm to the reference.
ca. 35cm
Ground
-11-
-12-
1
b
-13-
If the Big-Ski is
connected for the first
time or the sensor
combination has been
changed, the sensor
identification has to be
acknowledged by
pressing any button.
=
LED off
Averaging
=
LED on
The parameter
"Sensing mode" can
be reached by
pressing the A/M- and
the Set button
simultaneously.
A switch-back to
working mode is
made by pressing the
A/M-button. If no
button is pressed for
about 5 sec. the
controller switches
back automatically.
-14-
A switch-back to
working mode is made
by pressing the A/Mbutton. If no button is
pressed for about 5
sec. the controller
switches back
automatically.
6
b
7
> 1,5 Sek.
ca. 35cm
If the SET-button is
pressed for more than
1,5 seconds, the
display changes from
"SEt" to "0.0" and the
measured value and
the set point are both
set to zero.
-15-
Switch over to
automatic mode with
the A/M-button. The
function lamp "AUTO"
is on.
IMPORTANT!
1
9
ca. 35cm
ca. 35cm
ca. 35cm
1
1
In order to be able to
make corrections, the
set point can be
changed in the
automatic mode using
the UP/DOWNbuttons.
1
2 can switch back to
You
manual mode anytime
with the A/M-button.
The automatic control
of the valves will then
be switched off.
Sensitivity
IMPORTANT!
If the control works too sluggishly or too unstable in the automatic mode, the
sensitivity should be changed accordingly. (see section 4.4. of operating instruction
MOBA-matic Version 3.26).
Control window
The control window is active when the digital controller is operated with the BigSki. The setting of the control window is described in section 4.5 of operating
instruction MOBA-matic Version 3.26.
.
-16-
3. Technical data
Abmessungen (Dimensions):
140
120
152
63,5
280
306
Technische Daten
(Technical data):
Betriebsspannung (voltage range):
11 V ... 30 V (DC)
Stromaufnahme (current consumption):
Max. 300 mA
Zulssige Restwelligkeit (allowable residual
ripple):
+/- 10%
Erfassungsbereich (measuring range)
20cm - 100cm
80
Reproduzierbakeit (reproduceability):
+/- 1mm
Arbeitstemperaturbereich (ambient temperature range):
-10C ... +70C
Lagertemperaturbereich (storage temperature
range):
-25C ... +80C
Schutzart (enclosure protection):
IP 67
Gewicht (weight):
ca. 2,3 kg
-17-
Abmessungen (Dimensions):
AF
AF
AF
E
D
54
193
175
80
163
98
52
M6
Technische Daten
(Technical data):
Arbeitstemperaturbereich (ambient temperature range):
-10C ... +70C
Lagertemperaturbereich (storage temperature
range):
-25C ... +80C
Schutzart (enclosure protection):
IP 67
Schockbeanspruchung (shock resistance):
15g, 15ms
AF
G
B
C
Gewicht (weight):
ca. 1,2 kg
Farbe (colour):
RAL 1023, Mikrostruktur (microstructure)
-18-
E
D
The warranty statement is provided within the manual kit shipped with the machine.
English
CST