ABG 225-325

Full text

(1)Ref. No. VOE21A1004217 CPN 80846710 Printed in Sweden 2008-05 Volvo, Hameln. English CST.

(2) 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..

(3) Table of Contents INTRODUCTION PROCEDURE WHEN RECEIVING THE MACHINE ..................................................................... 0-3 DATA REQUIRED FOR ORDERING SPARE PARTS................................................................... 0-3 MACHINE IDENTIFICATION PLATE ....................................................................................... 0-3 ENGINE IDENTIFICATION PLATE .......................................................................................... 0-4 SAFEKEEPING THE OPERATING MANUAL AND FIRST AID BOX ............................................. 0-4. SAFETY EXPLANATION OF THE SAFETY SYMBOLS ........................................................................... 1-2 IMPORTANT GENERAL INFORMATION .................................................................................. 1-3 INTENDED AND UNINTENDED USE ...................................................................................... 1-4 INTENDED USE ........................................................................................................... 1-4 UNINTENDED USE....................................................................................................... 1-4 RESPONSIBILITIES OF THE USER / CONTRACTOR ................................................................. 1-5 RESPONSIBILITIES OF THE PERSONNEL .............................................................................. 1-7 INSTRUCTIONS FOR SPECIAL HAZARDS .............................................................................. 1-8 PRECAUTIONS FOR HANDLING HAZARDOUS GOODS ..................................................... 1-8 PRECAUTIONS WHEN HANDLING GAS HEATING SYSTEMS ........................................... 1-10 GAS HOSE ROUTING ......................................................................................... 1-12 SAFETY PRECAUTIONS WHEN GAS ESCAPES .............................................................. 1-13 SAFETY PRECAUTIONS WHEN THE MACHINE TOUCHES LIVE ELECTRIC CABLES ............. 1-14. INSTRUMENTS AND CONTROLS MACHINE OVERVIEW ......................................................................................................... 2-3 OPERATOR'S PLATFORM ................................................................................................... 2-4 OPERATOR'S SEAT............................................................................................................ 2-5 STANDARD SEAT ........................................................................................................ 2-5 DELUXE SEAT ............................................................................................................ 2-6 CONTROL PANEL .............................................................................................................. 2-7 EXTERNAL CONTROL PANELS .......................................................................................... 2-20 STORAGE COMPARTMENTS ............................................................................................. 2-22 FUEL TANK ..................................................................................................................... 2-23 CENTRAL LUBRICATION SYSTEM (OPTION)....................................................................... 2-24 MAT THICKNESS SCALES ................................................................................................. 2-25 EMULSION SPRAYING SYSTEM (OPTION).......................................................................... 2-26 POTENTIOMETERS FOR VIBRATORS AND TAMPERS ........................................................... 2-27 SWITCH OFF THE LEVELLING CYLINDERS IN CASE OF BREAKDOWNS ................................. 2-28 SCREED HEATING SYSTEM (OPTION)............................................................................... 2-30 ELECTRONIC LEVELLING SYSTEM (OPTION) ..................................................................... 2-32 ELECTRICS ..................................................................................................................... 2-33 BATTERY MASTER SWITCH ....................................................................................... 2-33 WORKING LIGHTS ..................................................................................................... 2-34 SOCKETS / FUSES ON THE PAVER'S LH REAR WALL.................................................. 2-35 SOCKETS ON THE PAVER'S RH REAR WALL .............................................................. 2-36 SOCKETS ON THE LH AND RH EXTERNAL CONTROL PANELS ..................................... 2-37 SWITCH CABINET ON THE OPERATOR'S PLATFORM .................................................... 2-38 SWITCH CABINET ON THE PAVER'S REAR WALL......................................................... 2-39 SOCKETS ON THE PAVER'S REAR WALL .................................................................... 2-40. Track Paver Titan 225/325. Ref. No. VOE21A1004217. 1.

(4) Table of Contents OPERATION IMPORTANT INSTRUCTIONS FOR OPERATION .......................................................................3-3 APPLICATION SPECIFIC SAFETY INSTRUCTIONS ...................................................................3-4 PAVING IN TUNNELS ....................................................................................................3-4 PAVING IN THE VICINITY OF OVERHEAD ELECTRIC CABLES .............................................3-4 PAVING IN CONTAMINATED AREAS ................................................................................3-4 PAVING IN THE VICINITY OF RAILWAY LINES ...................................................................3-4 PAVING ON SLOPES .....................................................................................................3-5 PAVING ON BRIDGES....................................................................................................3-5 COMMISSIONING THE PAVER ..............................................................................................3-6 CHECK BEFORE COMMISSIONING THE PAVER ...............................................................3-6 SWITCHING THE POWER SUPPLY ON AND OFF............................................................3-7 SETTING UP THE OPERATOR'S PLATFORM ....................................................................3-8 RAISING AND LOWERING THE SUN ROOF ..............................................................3-9 EXHAUST PIPE, FITTING AND REMOVING .............................................................3-11 FITTING THE SIDE CURTAINS ..............................................................................3-12 WINDSCREEN (OPTION), RAISING AND LOWERING ...............................................3-13 OPERATOR'S PLATFORM, EXTENDING AND RETRACTING ......................................3-14 SEAT CONSOLE, EXTENDING AND RETRACTING ...................................................3-15 CONTROL COLUMN, CROSS SLIDING ...................................................................3-16 OPERATOR'S SEAT, ADJUSTING (STANDARD SEAT) .............................................3-17 OPERATOR'S SEAT, ADJUSTING (DELUXE SEAT) .................................................3-18 STARTING THE ENGINE ..............................................................................................3-19 STARTING THE ENGINE WITH THE STARTER BATTERIES .......................................3-20 JUMP STARTING THE ENGINE .............................................................................3-21 STOPPING THE ENGINE..............................................................................................3-23 STARTING AND STOPPING THE PAVER ..............................................................................3-24 DRIVING THE PAVER ON ROADS AND JOB-SITES .........................................................3-25 TURNING ON-THE-SPOT) ............................................................................................3-27 OPERATING THE PAVER IN AUXILIARY CONTROL (EMERGENCY CONTROL) ...................3-28 STARTING THE PAVER ........................................................................................3-28 STOPPING THE PAVER ........................................................................................3-28 PREPARING THE PAVER FOR OPERATION ..........................................................................3-29 REFUELLING THE PAVER............................................................................................3-30 LUBRICATING THE PAVER ...........................................................................................3-32 FRONT CROSS BEAM ................................................................................................3-34 ROAD SCRAPERS, RAISING AND LOWERING................................................................3-35 LOWERING THE ROAD SCRAPERS .......................................................................3-35 RAISING THE ROAD SCRAPERS ...........................................................................3-35 ADJUSTING THE ROAD SCRAPERS ......................................................................3-35 HOPPER WINGS, OPEN AND CLOSE ...........................................................................3-36 HOPPER WINGS, OPEN AND CLOSE ....................................................................3-36 SCREED TRANSPORT LOCK .......................................................................................3-36 RAISING AND SECURING THE SCREED IN THE TRANSPORT LOCK..........................3-38 RELEASING AND LOWERING THE SCREED FROM THE TRANSPORT LOCK ...............3-38 VARIOMATIC SCREED, EXTEND AND RETRACT ............................................................3-39 SCREED TENSIONING DEVICE, ASSEMBLING AND DISMANTLING ...................................3-40 SCREED SPACER BLOCKS (OPTION) ..........................................................................3-42 FITTING THE SCREED SPACER BLOCKS ...............................................................3-42 REMOVING THE SCREED SPACER BLOCKS ..........................................................3-42 AUGER HEIGHT ADJUSTMENT ....................................................................................3-42 ADJUSTING THE HEIGHT OF THE BASIC AUGERS..................................................3-44 ADJUSTING THE HEIGHT OF THE AUGERS WITH OUTER BEARINGS .......................3-45 FITTING AUGER EXTENSIONS .....................................................................................3-46 AUGER CONTROL, ADJUSTING ...................................................................................3-49. 2. Track Paver Titan 225/325.

(5) 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. Track Paver Titan 225/325. 3.

(6) Table of Contents DRIVE CHAINS AND V-BELTS ......................................................................................4-21 V-BELTS ............................................................................................................4-22 DRIVE CHAINS ....................................................................................................4-23 TENSIONING THE CONVEYORS ............................................................................4-24 AUGER CENTRE DRIVE.......................................................................................4-25 AUGER OUTER DRIVES ......................................................................................4-26 PRESERVATION FOR LONGER PERIODS OF STANDSTILL .....................................................4-27 LUBRICATION PLAN ..........................................................................................................4-28 GREASE POINTS .......................................................................................................4-29 CENTRAL LUBRICATION SYSTEM (OPTION) .................................................................4-32 OIL CHANGE, TRANSMISSION GEARS .........................................................................4-33 OIL CHANGE, PUMP DISTRIBUTOR GEAR....................................................................4-34 OIL CHANGE, HYDRAULIC SYSTEM .............................................................................4-36 OIL CHANGE, DIESEL ENGINE ....................................................................................4-38. TROUBLE SHOOTING TROUBLE SHOOTING ...................................................................................................5-3 FUSES AND RELAYS ...........................................................................................................5-6 TOWING THE PAVER ..........................................................................................................5-7 MANUALLY RELEASING THE PARKING BRAKE .................................................................5-8 RELEASING THE HYDRAULIC DRIVE MOTORS TO RUN FREELY ......................................5-9 REMOVING PAVING MATERIAL FROM THE AUGER CHANNEL ........................................5-10. TECHNICAL DATA TITAN 225 .........................................................................................................................6-2 GENERAL DATA ...........................................................................................................6-2 NOISE AND VIBRATION VALUES ....................................................................................6-4 DIMENSIONS ...............................................................................................................6-5 TITAN 325 .........................................................................................................................6-6 GENERAL DATA ...........................................................................................................6-6 NOISE AND VIBRATION VALUES ....................................................................................6-8 DIMENSIONS ...............................................................................................................6-9. CONSUMABLES LIST OF FUEL OILS AND LUBRICANTS..................................................................................7-3. TORQUES FOR THREADED CONNECTIONS TABLE OF TORQUES - ISO ................................................................................................8-2. GLOSSARY OF TERMS ALPHABETICAL INDEX .........................................................................................................9-II. 4. Track Paver Titan 225/325.

(7) INTRODUCTION. Track Paver Titan 225/325. 0-1.

(8) INTRODUCTION. INTRODUCTION This operating manual provides the operators and maintenance personnel on the job-site with vital instructions, rules and criteria for operating and servicing the track paver model Titan 225/ 325. The operator must carefully read and understand the operating and maintenance manual before operating the machine. The operating manual contains the following chapters: •. INTRODUCTION. •. Chapter 1, SAFETY. •. Chapter 2, INSTRUMENTS AND OPERATING CONTROLS. •. Chapter 3, OPERATING INSTRUCTIONS. •. Chapter 4, MAINTENANCE. •. Chapter 5, TROUBLE SHOOTING. •. Chapter 6, TECHNICAL SPECIFICATION. •. Chapter 7, FUEL AND LUBRICANT SPECIFICATIONS. •. Chapter 8, TORQUE SPECIFICATIONS. If any part of this manual cannot be understood, contact your supervisor or local distributor. The operators and maintenance personnel must understand the instructions contained in this manual. This is an essential condition for working safely with the machine. The correct machine operation, use and regular maintenance are also essential elements to provide the highest performance and safety. Remarks:No part of this operating manual may be reproduced, stored in electrical data systems, processed, copied or published in any way without prior written approval by the manufacturer. All rights for copying, distribution and translation are reserved by the manufacturer. Remarks:Machines may be illustrated in this manual equipped with accessories.. 0-2. Track Paver Titan 225/325.

(9) INTRODUCTION. PROCEDURE WHEN RECEIVING THE MACHINE Your machine has been tested, accurately checked and prepared for shipment before leaving the factory. Upon receipt, check the machine for transport damage and missing parts.Use the shipping documents sent with the machine and your purchase order to make a complete check of the equipment. Immediately inform the carrier if the machine is damaged or any parts are missing.He will tell you what to do in cases of a claim.. DATA REQUIRED FOR ORDERING SPARE PARTS An exact description of the model and serial number of your machine will facilitate a fast and efficient response from our spare parts and service departments. Always have the model and serial number of your machine close at hand when contacting your local spare parts and service organisation. We advise you to enter your machine data in the following lines so that they are always available when required: Model ....................................... Serial No. ................................. Year of manufacture................. Engine Serial No. and type of engine.......................................... MACHINE IDENTIFICATION PLATE The machine's identification plate (1) is located on the RH side of the machine at the rear of the cover plate. Illustration 1: Machine Identification Plate. Track Paver Titan 225/325. 0-3.

(10) INTRODUCTION. ENGINE IDENTIFICATION PLATE The engine serial number is marked on the engine's identification plate (2). Illustration 2: Engine Identification Plate. SAFEKEEPING THE OPERATING MANUAL AND FIRST AID BOX Safely store the operating manual for the paver, the screed, the engine and for other options in the storage compartment (3) for the first aid box. Renew any documents if they have become illegible. Remarks:Ensure the first aid box is always stored in this storage compartment.The contents of the first aid box must be complete and in a perfect condition. Regularly check the first aid box and renew any missing or outdated items. Illustration 3: Storage compartment for the first aid box and documentation. 0-4. Track Paver Titan 225/325.

(11) CHAPTER1- SAFETY. Track Paver Titan 225/325. 1-1.

(12) Chapter 1. SAFETY. SAFETY Closely observe the recommended precautions and instructions for safely operating the machine.. EXPLANATION OF THE SAFETY SYMBOLS Safety symbols used in this manual. They indicate a potential danger. Closely observe all safety symbols to avoid fatal accidents, injuries and damage to property and the environment.. !. DANGER (Red background). !. WARNING. The safety symbol "DANGER" indicates a specially dangerous situation. Fatal accidents or serious injuries will occur if this symbol is not observed. The safety symbol "WARNING" indicates a potentially dangerous situation. Fatal accidents or serious injuries CAN occur if this symbol is not observed.. (Orange background). !. CAUTION. (Yellow background). NOTICE. The safety symbol "CAUTION" indicates a potentially dangerous situation. Minor or medium injuries or damage to the environment CAN occur if this symbol is not observed. The safety symbol "NOTICE" draws attention to special assembly, operating or maintenance instructions not directly connected with danger.. (Blue background) REMARKS: Remarks contain information for the efficient application of the machine. PLEASE NOTE: Contains general information not connected with danger.. 1-2. Track Paver Titan 225/325.

(13) SAFETY. Chapter 1. IMPORTANT GENERAL INFORMATION Closely observe the following before operating or servicing the machine: •. The manufacturer cannot predict all potential hazards which can expose personnel to danger. The warning symbols in this manual and the warning symbols on the machine cannot advert all potential hazards.. •. The machine has been designed and manufactured in accordance with the current norms, standards and recognised safety regulations. In spite of this, improper use can lead to serious injury or even death of the operator or other persons. Damage may also occur on the machine, to property and the environment.. •. All locally prevailing accident prevention regulations, directives and laws must be strictly observed. These still apply although they are not specifically mentioned in this manual. The user is solely responsible for ensuring these regulations, directives and laws are strictly complied with.. Track Paver Titan 225/325. 1-3.

(14) Chapter 1. SAFETY. INTENDED AND UNINTENDED USE INTENDED USE The Titan paver has been designed for paving all kinds of asphalt materials, cement treated aggregates, graded aggregates, sand and gravel which are paved to generally recognized standards. Other materials should not be paved with the paver. The paver may only be operated on a specially prepared surface with sufficient bearing capacity. Adhere to all application conditions specified.The specified maximum slope (< 25 %) must be maintained without fail. The machine must be secured by a suitable means if your paving project requires a special paver application.The surface must be firm with sufficient bearing capacity when operating on special paver applications. Before using the machine for special applications, obtain information from the manufacturer on its ability to perform such work. All functional faults, especially those which effect the safety of the machine, must be immediately rectified.We recommend the exclusive use of genuine accessories and spare parts. We cannot ensure the suitability and quality of other parts and cannot accept any liability for damage and accidents resulting from the use of such parts. Intended use also includes closely observing the operating instructions and adhering to the service and maintenance intervals.. UNINTENDED USE The manufacturer accepts no liability whatsoever for damage caused by unintended use. The risks arising from an unintended use of the machine are borne entirely by the user. Unintended use of the machine includes: •. Transporting loads.. •. Towing or recovering other vehicles.. •. For compacting on hard bases (e.g. concrete or frozen soil).. •. Operating the machine in areas where there is a danger of an explosion.. •. Operating the machine in public traffic.. •. Operating the machine in closed or poorly ventilated areas. Remarks: There is no warranty for the safe operation of the paver if it is put to unintended use. The manufacturer does not accept any liability whatsoever for personal injury or damage to property if the machine is put to an unintended use.. 1-4. Track Paver Titan 225/325.

(15) SAFETY. Chapter 1. RESPONSIBILITIES OF THE USER / CONTRACTOR The paver can only operate safely on the job-site if all necessary safety measures have been taken. It is the responsibility of the user/contractor to plan implement all necessary safety measures and ensure they are strictly observed. As the user / contractor please ensure that: •. The machine is only operated for its intended use.. •. The machine is only used in a perfect functional and operating condition and with all safety devices supplied with the machine.. •. All maintenance and service intervals are strictly adhered to. The correct function of all safety devices must be regularly checked.. •. Only fully qualified persons carry out work on the machine. The personnel assigned to work on the machine must be suitably trained and have adequate experience in handling such equipment and qualified for performing the respective work. The manufacturer offers suitable training courses for the personnel.. •. Any work on the machine's electrical system and equipment may only be performed by a trained assistant electrician or a similarly trained person whereby they are supervised and controlled by a fully trained and qualified electrician. This work must be carried out in accordance with your locally prevailing electro-technical regulations and directives.. •. Ensure that the gas heating system is operated and maintained by fully qualified and authorized personnel who have been thoroughly instructed in the operation and maintenance of the system and from whom it is expected that they will carry out the work in a reliable manner.. •. Work on the machine's chassis, the brakes, the hydraulics and the steering system may only be carried out by fully qualified personnel who have been appropriately trained and have the required skills.. •. The personnel must be regularly trained in all matters of occupational health and safety as well as environment protection. The personnel must be aware of and observe all regulations concerning hazardous goods and materials. All locally prevailing laws and regulations must be complied with.. •. The personnel must be told to read the operating manual and especially the safety instructions included in the manual.It is the owner's / contractor's responsibility to ensure his personnel has read and understood the operating manual.. •. The documentation is safely stored in the compartment provided on the machine. The documentation must always be close at hand on the machine. The operating instructions must be supplemented by detailed working instructions appropriate to the individual job-site.. •. The required protective clothing must be made available to the personnel for operating, servicing and repairing the machine. The personnel must be instructed to wear protective clothing at all times.All necessary safety precautions must be taken on the job-site.. Track Paver Titan 225/325. 1-5.

(16) 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.. Track Paver Titan 225/325.

(17) SAFETY. Chapter 1. RESPONSIBILITIES OF THE PERSONNEL All personnel must ensure the following: •. Thoroughly read the operating manual.You must be able to operate the machine safely and know and understand all procedures for safely carrying out maintenance work.. •. Always take the prescribed safety precautions and wear protective clothing for your personal protection.. •. Operators and maintenance personnel must exercise extreme caution and foresight when performing work to recognise potential hazards.. •. Operators with long hair must tie it into a bun or wear a protective helmet; wear overalls that fit snug to the body and remove all rings and jewellery.Loose overalls, long hair and jewellery may become entangled in the machine. This can lead to serious injuries and fatal accidents.. •. Contact your supervisor or your nearest authorised distributor if you have any questions concerning the safe handling and maintenance of your machine. NEVER WORK ON AN ASSUMPTION, carry out an inspection.. •. The machine is only used in a perfect functional and operating condition and with all safety devices supplied with the machine.. •. Immediately stop the machine if a functional fault occurs. The faulty function must be immediately reported to your supervisor / responsible department.. •. Never perform maintenance work when the engine is running and the hydraulics are under pressure. Before starting any work on the machine, ensure it cannot be switched on, secure it against rolling off and lower the screed.. •. Modifications or alterations affecting the safety of the machine may not be carried out without prior approval by the manufacturer. This applies to the installation and adjustment of safety devices and valves as well as welding work on load bearing assemblies and elements.. •. Always adhere to the specified intervals for service and maintenance work.. •. Avoid a risky manner of driving and operation.. Track Paver Titan 225/325. 1-7.

(18) Chapter 1. SAFETY. INSTRUCTIONS FOR SPECIAL HAZARDS PRECAUTIONS FOR HANDLING HAZARDOUS GOODS The following information provides instructions for the correct handling of hazardous materials from machines. Further information can be obtained from your nearest distributor.. !. CAUTION. The following emission will be a health hazard if not properly handled (refer to Table1). Table 1: Precautions for Handling Hazardous Materials Emission. Precaution. Engine exhaust. Do not inhale. Avoid an accumulation of exhaust fumes in closed rooms.. Particles of dust from an electric motor / generator (brushes / insulation). Avoid inhaling dust particles during maintenance work.. !. CAUTION. The following emission will be a health hazard if not properly handled (refer to Table2). Table 2: Precautions for Handling Hazardous Goods Material. 1-8. Precaution. Anti-freeze solution (water cooled engine). Avoid inhaling, swallowing and skin contact; do not allow to penetrate the environment.. Hydraulic oil. Avoid inhaling, swallowing and skin contact; do not allow to penetrate the environment.. Engine oil. Avoid inhaling, swallowing and skin contact; do not allow to penetrate the environment.. Grease. Avoid inhaling, swallowing and skin contact; do not allow to penetrate the environment.. Corrosion protection. Avoid inhaling, swallowing and skin contact; do not allow to penetrate the environment.. Track Paver Titan 225/325.

(19) SAFETY. Chapter 1. Material. Precaution. Fuel. Avoid inhaling, swallowing and skin contact; do not allow to penetrate the environment. Fuel is highly inflammable;when handling fuel, ensure there are no sparks or naked flames in the far-reaching surroundings. Do not smoke when refuelling.. Battery water. Avoid inhaling, swallowing and skin contact; do not allow to penetrate the environment.. Gear oil. Avoid inhaling, swallowing and skin contact; do not allow to penetrate the environment.. Track Paver Titan 225/325. 1-9.

(20) Chapter 1. SAFETY. PRECAUTIONS WHEN HANDLING GAS HEATING SYSTEMS This chapter contains important instructions for the gas heating system on the paving screed if your paver is equipped with this option.. !. DANGER. Liquid gas is highly inflammable and burns explosively.Liquid gas is heavier than oxygen, it sinks to the ground and displaces the oxygen. This results in a danger of suffocation. Closely observe the following safety instructions to avoid serious injury and damage to property. •. The gas heating system may only be operated and serviced by qualified and authorised personnel who have been specially trained in the operation and maintenance of such systems.. •. Ensure the complete gas heating system is checked by a fully qualified and authorized person as follows: — Before using the gas heating system for the first time, ensure that it is correctly installed and has no gas leaks. — Check the working safety of the system on completion of all maintenance and repair work. — Check the working condition, function, installation and gas leaks in the system if it has been out of operation for more than one year.. 1-10. •. Your locally prevailing regulations for checking gas bottles still apply and are not effected by this chapter.. •. All gas connections must be checked for leakage and damage.Only use gas detectors approved for gas systems.Searching for gas leaks with a naked flame is a deadly peril and listening for escaping gas is not a safe method either. Do not use the gas heating system if the hoses or connections are porous or damaged.. •. Only operate the gas heating system in open and well ventilated areas.. •. Protect the gas heating system from direct sun rays and other sources of heat (max. 50 °C). Cover the gas bottles with the canopies supplied with the paver.. •. Close the valves on the gas bottles by turning them clockwise when the gas heating system is not in use, e.g. during breaks in paving and when working on the system. Disconnect, remove and properly store the gas bottles during longer standstill times.. •. The gas heating system must be switched off during cleaning work.. Track Paver Titan 225/325.

(21) SAFETY. Chapter 1 •. When performing any work on the gas heating system, ensure there are no sources of ignition within a radius of 10 metres.Do not smoke, do not ignite any naked flames and do not switch on any electrical appliances within this safety radius (danger of flashover).. •. Safely mount the gas bottles on the paver using the supports and brackets provided and ensure they are secured against rotating or falling over. Only withdraw gas from the bottles when they are in an upright position.. •. During operation, the gas bottles should not be allowed to become under-cooled as this may cause an interruption in the flow of gas. Icing on the bottles caused by an exceptionally high withdrawal of gas must be allowed to thaw off using warm air or warm water with a temperature not exceeding 50°[C]. Never use a naked flame, red hot objects or convector heaters to thaw off the gas bottles. Icing must not be hammered off the gas bottles or removed mechanically in a similar manner.. •. When replacing hoses, ensure the new hoses and connections are suitable for gas heating systems and are routed in such a way to protect them from chemical, thermal and mechanical damage.. •. The gas heating system may only be operated using a pressure control valve with integrated leak tester and hose rupture safety control.. •. Leaky gas bottles must be immediately removed from the danger zone, if this is possible without submitting yourself to danger and be appropriately marked.. •. Never operate the gas heating without the ventilation system correctly installed and keep the ventilation intake and outlet apertures free from blockages to ensure an adequate natural ventilation.. •. Fire and explosion precautions must be taken if the heating system is operated in buildings or areas where explosive gases can be reckoned with. Keep all combustible objects and cleaning cloths which may ignite away from hot parts on the heating system.. •. Parts in the heating system which are subject to wear and deterioration must be renewed after 8 years at the latest. An exception to this rule is when a specialist confirms their perfect working condition.. •. In case of fire, remove the gas bottles to a safe area and keep them cool but do not subject yourself to danger.. •. Store the gas bottles correctly: — Fit the cap nut and protective cap to the gas bottle valve. — Never store the gas bottles below ground level (burrows and basements), in living accommodation and restrooms or in their vicinity and in thoroughfares. — Always store gas bottles in an upright position - even empty bottles.. Track Paver Titan 225/325. 1-11.

(22) Chapter 1. SAFETY. Gas Hose Routing. !. CAUTION. The hose rupture protector (4) must never be removed or installed in another position. Illustration 2. Table 3: Schematic illustration of the propane gas heating system. 1-12. 1. Gas bottle with canopy. 11. Ignition electrode. 2. Stop valve, gas bottle valve. 12. Thermo element. 3. Medium pressure controller. 13. Gas burner, basic screed. 4. Hose rupture protector. 14. Sieve. 5. Distributor with 2 stop valves. 15. Solenoid valve. 6. High pressure hose 6x5. 16. Regulator and stop valve. 7. Start button. 17. Ignition warning lamp. 8. Stop button. 18. Operating warning lamp. 9. Safety valve. 19. Gas burner, Vario screed section. 10. Burner. 20. Gas burner, 1000 mm screed extension. Track Paver Titan 225/325.

(23) SAFETY. Chapter 1. SAFETY PRECAUTIONS WHEN GAS ESCAPES. !. DANGER. Proceed as follows if you notice gas is escaping: •. Warn other people in the vicinity and instruct them to leave the danger zone.. •. Immediately close the valves on the gas bottles. NOTE: To close the bottle, turn the screw on the valve clockwise.. •. Ensure there is ample ventilation.. •. Extinguish all naked flames, cigarettes and other sources of ignition in the vicinity.. •. Do not switch on any electrical appliances because a flashover to the switching contact may occur and ignite the gas mixture.. •. If there is a danger that escaping gas cannot be brought under control or there is a danger of fire in the area of the heating system, immediately alarm the fire brigade and try to extinguish the fire yourself but do not subject yourself to danger. Immediately clear the danger zone of all persons.. Track Paver Titan 225/325. 1-13.

(24) Chapter 1. SAFETY. SAFETY PRECAUTIONS WHEN THE MACHINE TOUCHES LIVE ELECTRIC CABLES When paving, always keep the machine at an adequate safety distance to overhead electric cables. If work must be carried out in the vicinity of overhead electric cables, then ensure there is an adequate safety distance between the cables and parts and components on the paver.. !. DANGER. Proceed as follows if the machine touches live electric cables:. 1-14. •. Remain seated on the operator's seat.. •. Do not touch any operating controls or any other parts of the machine.. •. Warn other persons not to touch the machine.. •. Have the current switched off at source.. •. Only leave the machine when you are absolutely sure that the damaged cable is dead.. Track Paver Titan 225/325.

(25) CHAPTER 2 - INSTRUMENTS AND CONTROLS. Track Paver Titan 225/325. 2-1.

(26) Chapter 2. INSTRUMENTS AND CONTROLS. INSTRUMENTS AND CONTROLS. !. WARNING. In the interest of your own safety and the safety of others, you must thoroughly read and understand this chapter before operating the machine.. 2-2. Track Paver Titan 225/325.

(27) INSTRUMENTS AND CONTROLS. Chapter 2. MACHINE OVERVIEW Illustration 1:. Table 1: Pos.. Description. Function. 1. Sun roof. All weather protection. 2. Operator's platform with control panel. Operating the paver. 3. First aid box compartment. Storing the first aid box and operating manual. 4. Mat thickness scales. Indicates the approx. paving thickness. 5. Hopper with conveyors. Loading the paver and conveying the material to the augers. 6. Outrigger for direction indicator. Assist steering the machine during paving (e.g. along a taught reference wire). 7. Front Cross Beam. Pushing the dump truck. 8. Road Scrapers. Clearing the surface in front of the undercarriage. 9. Crawler Unit. Driving the paver. 10. Fuel Tank. Refuelling the paver. 11. Distributor augers. Distributing the material in front of the screed. 12. Towing arms. Raising and lowering the paving screed. 13. Paving screed. Compacting the material;Information on the paving screed is included in the screed's documentation. 14. Gas bottle support. Mounting the gas bottles for the screed heating system. 15. External control panel. Operating the screed. 16. Emulsion spraying system. Cleaning the paver (Option). Track Paver Titan 225/325. 2-3.

(28) Chapter 2. INSTRUMENTS AND CONTROLS. OPERATOR'S PLATFORM Illustration 2. Table 2: Pos.. 2-4. Description. Function. 1. Control panel cover. Protects the control panel from rain and dirt. 2. Staple for padlock. Protection against vandalism. 3. Guide tube. Cross-sliding the control column. 4. Locking bolt hole. Secures the control panel against unintentional movement. Track Paver Titan 225/325.

(29) INSTRUMENTS AND CONTROLS. Chapter 2. OPERATOR'S SEAT STANDARD SEAT. !. CAUTION. Sudden movements of the seat will cause injuries. Ensure that all adjusting levers lock into position after adjusting the seat. Only adjust the seat when the machine is at a standstill. Illustration 3:. Table 3: Pos.. Description. Function. 1. Lever "operator's weight". Setting the operator's weight. 2. Lever "seat to & fro". Longitudinal seat adjustment. 3. Lever "backrest to & fro". Adjusting the backrest inclination. Armrest. Armrest raise and lower. A-B. Track Paver Titan 225/325. 2-5.

(30) Chapter 2. INSTRUMENTS AND CONTROLS. 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. 1. Lever "seat to & fro". Longitudinal seat adjustment. 2. Lever "seat height / slope". Adjusting the seat height and slope. 3. Lever "backrest to & fro". Adjusting the backrest inclination. 4. Lever "operator's weight". Setting the operator's weight. 5. Button switch "seat heating" (Option). Seat heating Front LH switch: Seat heating ON / OFF Rear RH switch: Backrest heating ON / OFF. 2-6. Track Paver Titan 225/325.

(31) INSTRUMENTS AND CONTROLS. Chapter 2. CONTROL PANEL Illustration 5:. Table 5: Pos.. Illustration. Description. Function. A1. Control lamp,engine oil temperature. Shows the temperature of the engine oil. The indicator needle must be in the green range during operation. If the needle moves into the red range, immediately stop the engine and eliminate the cause of overheating (e.g. engine overloaded, loss of coolant, dirty radiator).. A2. Fuel level indicator. Shows the level of fuel in the fuel tank. The exact level can only be shown when the machine is standing on level ground.. A3. Track Paver Titan 225/325. No function has been allocated to this key. 2-7.

(32) Chapter 2. Pos.. 2-8. INSTRUMENTS AND CONTROLS. Illustration. Description. Function. A4. Operating hour meter. Shows the machine's number of operating hours.. A5a. Road lights. No function has been allocated to this key. A5b. Flashing direction indicators. No function has been allocated to this key. A5c. Battery charging lamp. Illuminates if the battery is not being charged due to a faulty generator or fault in the electrical system.. A5d. Control lamp engine oil pressure. Illuminates red if the oil pressure is too low (e.g. oil level too low). Immediately switch off the engine. An acoustic warning will sound 4 minutes after the red lamp illuminates.. A6a. Control lamp, engine coolant level. Illuminates red if the coolant level is too low. Let the engine run at idling speed for a few minutes and then switch it off. An acoustic warning will sound at the same time.Caution: Let the engine cool down before checking the coolant level. Also observe the "engine oil temperature" warning (A1).. A6b. Control lamp emergency STOP. Illuminates red when the emergency STOP button (A11) is pressed.. A6c. Control lamp hydraulic oil temperature. Illuminates red if the hydraulic oil temperature is too high. Immediately stop the paver. Let the engine run at a medium speed with the machine at a standstill to cool down the hydraulic oil.. Track Paver Titan 225/325.

(33) INSTRUMENTS AND CONTROLS. Pos.. Illustration. A6d. Chapter 2. Description. Function. Control lamp spring loaded brake. Illuminates red when the brake is applied a) when the paver is switched OFF b) when the ignition is switched ON but the engine has not been started c) when the drive lever (A25) is in the zero position and the engine is running.. A7. Toggle switch, vibration. Select the operating mode for the vibration. Centre Position: Neutral, the vibrators are switched OFF. LH Position (MAN): The vibrators run permanently (for cleaning purposes or adjusting the hydraulics). RH Position (AUTO): The vibrators are switched ON when the drive lever (A25) is moved to the forward travel position. The vibrators are switched OFF when the drive lever is returned to the centre position. This mode is recommended for paving work.. A8a. Toggle switch, tampers. Select the operating mode for the tampers. Centre Position: Neutral, the tampers are switched OFF. LH Position (MAN): The tampers run permanently (for cleaning purposes or adjusting the hydraulics). RH Position (AUTO): The tampers are switched ON when the drive lever (A25) is moved to the forward travel position. The tampers are switched OFF when the drive lever is returned to the centre position. This mode is recommended for paving work.. Track Paver Titan 225/325. 2-9.

(34) Chapter 2. Pos. A8b. INSTRUMENTS AND CONTROLS. Illustration. Description Potentiometer, heavy duty tampers. Function Potentiometer for setting the tamper frequency. Potentiometer only with heavy duty tampers (variable displacement pump); refer to 227Page, Pos. 2.. A9. Speed potentiometer. Potentiometer for preselecting the travelling speed. The range of travelling speeds depends on the position of the speed stage toggle switch A13. Toggle switch A13 on Pos. L: 0 - 16 m/min (paving speed range) Toggle switch A13 on Pos. H: 0 - 60 m/min (transport speed range) A constantly controlled speed is only possible at a potentiometer setting of 0:7 m/min and higher.. A10. Control lamp, rapid lubrication. Activate the rapid lubrication at the end of daily paving work; the control lamp illuminates during the lubrication process.. A11. Emergency STOP button. Released: Normal operation. Release button for emergency STOP. Depressed: Emergency STOP released.. A12. Depressed: All drives and movements are stopped; the spring loaded brake is applied.. The emergency STOP button (A11) must be pulled upwards to release the emergency stop.. 2-10. Track Paver Titan 225/325.

(35) INSTRUMENTS AND CONTROLS. Pos.. Illustration. A13. Chapter 2. Description Toggle switch, speed stage selector switch. Function Switch for selecting the required speed stage. LH Position (L): Paving speed (Low, 0 - 16 m/min) RH Position (H): Transport speed (High, 0 - 60 m/min) The paver will automatically stop when changing speed stages onthe-run. Thereafter, turn the speed potentiometer to start the paver again.. A14. Toggle switch, turning on the spot. Used for turning the paver on the spot. This function can only be activated when the drive lever (A25) is in the zero position and the and the toggle switch (A13) for the speed stage selection has been moved to the LH position "L" (paving speed stage). LH Position (0): neutral Move the switch to the RH position (I): Turning on-the-spot function is activated. Rotate the steering potentiometer (A26) to select the direction for turning on-the-spot. The more you rotate the steering potentiometer (A26), the faster the paver will turn.. A15. Track Paver Titan 225/325. No function has been allocated to this key. 2-11.

(36) Chapter 2. Pos. A16. INSTRUMENTS AND CONTROLS. Illustration. Description Toggle switch, RH tow point. Function Toggle switch for altering the paving thickness on the RH side. The tow point can only be manually adjusted when the toggle switch (A35) for the levelling system has been moved to the MAN mode. Centre Position: neutral Move the switch to the rear (upwards): Increase the mat thickness Move the switch to the front (downwards): Reduce the mat thickness. A17. Toggle switch, RH auger operating mode. Select the operating mode of the RH auger. LH Position (MAX): Maximum auger speed.In this position the auger will rotate even when the electronic control fails. RH Position (PROP): Proportional auger speed control according to material requirements (controlled by ultrasonic sensors). A18. Toggle switch, RH Auger ON/OFF control. RH auger ON / OFF control. Centre Position: Auger is switched OFF. Move the switch to the left (MAX): The auger will rotate in the mode selected with the toggle switch A17. Move the switch to the right (AUTO): The auger will be proportionally controlled by the ultrasonic sensor.. A19. Toggle switch, RH conveyor operating mode. RH conveyor ON / OFF. Centre Position: Conveyor is switched OFF. LH Position (MAN): Conveyor is manually switched ON and OFF. RH Position (AUTO): The conveyor is controlled by the RH paddle type control switch.. 2-12. Track Paver Titan 225/325.

(37) INSTRUMENTS AND CONTROLS. Pos.. Illustration. A22. Chapter 2. Description Toggle switch, hopper wings. Function Hopper wings open and close. Centre Position: neutral Move the switch to the rear (upwards): Close the hopper wings. Move the switch to the front (downwards): Open the hopper wings. Mechanically secure the closed hopper wings with the locking bolts when transporting the paver.. A21. Toggle switch, Auger reverse mode. Determine the direction of rotation on both auger halves. Centre Position: neutral, the auger halves will convey the material outwards on both sides. LH Position: Both augers will convey the material to the LH side. RH Position: Both augers will convey the material to the RH side.. A22. Button switch, warning horn. Press the button to sound the warning horn. Sound the warning horn before moving the paver to warn other persons in the danger zone.. A23. Track Paver Titan 225/325. Control lamp, rotary sensor. Flashes if the rotary sensor or its wiring fails on the RH or LH transmission gear.. 2-13.

(38) Chapter 2. Pos. A24. INSTRUMENTS AND CONTROLS. Illustration. Description Ignition switch. Function Starting and stopping the engine From left to right: Position „P“: Parking position (P), the ignition key can be removed Position „0“: Engine cut-out (before stopping the engine, let it run for approx. 5 minutes without load at a higher speed to cool down). Position „1“: Switch on the ignition; the control lamps will illuminate Position „2“: Start the engine To start the engine, the drive lever (A25) must be in the neutral position.. A25. Drive lever. For driving the paver forward or backward up to the speed set on the speed potentiometer (A9). Release the drive lever by placing two fingers underneath and either side of the knob and lifting it gently. Centre Position: neutral, the pave is at a standstill and the spring brake is applied. Gently move the drive lever forwards as far as it will go: The paver travels forwards Gently move the drive lever backwards as far as it will go: The paver travels backwards All automatic functions (except the conveyors) can only be activated when the paver is travelling forwards.. 2-14. Track Paver Titan 225/325.

(39) INSTRUMENTS AND CONTROLS. Pos.. Illustration. A26. Chapter 2. Description Steering potentiometer. Function For steering the paver Centre Position: The paver travels straight ahead. Rotate to the left: The paver will travel in a left turn Rotate to the right: The paver will travel in a right turn. A27. Toggle switch, screed assist (Option). Screed assist ON / OFF. The screed assist prevents the screed sinking downwards during paving work and improves the paver's traction. If required, a variable pressure between 10 and 50 bar can be applied to the screed transport cylinders. This pressure counteracts the weight of the screed and prevents it sinking into paving material with a low bearing capacity. This option does not effect the screed's floating behaviour; the screed will bear down on the material with a reduced load. LH Position (ON): Screed assist is switched ON RH Position(OFF): The screed assist is switched OFF. Track Paver Titan 225/325. 2-15.

(40) Chapter 2. Pos. A28. INSTRUMENTS AND CONTROLS. Illustration. Description Toggle switch, screed anti-climbing lock (Option). Function Screed anti-climbing lock ON / OFF. If required, the screed transport cylinders can be hydraulically locked in position to prevent the screed from raising. The anti-climbing lock prevents the screed from climbing up and over paving material which has cooled down in front of the screed when the machine starts moving again after a stop in paving work. The screed anti-climbing lock will only function with the drive lever moved to the forward travel position and the screed switched to the floating mode. LH Position (ON): The screed anti-climbing lock will be switched on for approx. 10 seconds when the machine starts paving. RH Position(OFF): The screed anti-climbing lock is switched off.. A29. Toggle switch, screed floating mode. Screed floating mode ON / OFF. LH Position (0): The screed can be manually raised and lowered using the toggle switch (A31). RH Position (1): Screed floating mode Only switch on the floating mode after the screed has been lowered e.g. resting on squared timbers Ensure no persons are in the danger zone when raising or lowering the screed or during transport.. A30. 2-16. Control lamp,screed floating mode. Illuminates when the screed has been switched to the floating mode (toggle switch A29 moved to position 1).. Track Paver Titan 225/325.

(41) INSTRUMENTS AND CONTROLS. Pos.. Illustration. A31. Chapter 2. Description Toggle switch, Screed raise / lower. Function Screed raise and lower Move the switch to the rear:Screed raise Move the switch to the front (downwards): Screed lower. A32. Toggle switch, LH auger operating mode. Select the operating mode of the LH auger. LH Position (MAX): Maximum auger speed. RH Position (PROP): Proportional auger speed control according to material requirements.. A33. Toggle switch, LH Auger ON/OFF control. LH auger ON / OFF control. Centre Position: Auger is switched OFF. Move the switch to the left (MAX): The auger will rotate in the mode selected with the toggle switch A32. Move the switch to the right (AUTO): The auger will be proportionally controlled by the ultrasonic sensor.. A34. Toggle switch, LH conveyor operating mode. LH conveyor ON / OFF. Centre Position: Conveyor is switched OFF. LH Position (MAN): Conveyor is manually switched ON and OFF. RH Position (AUTO): The conveyor is controlled by the LH paddle type control switch.. Track Paver Titan 225/325. 2-17.

(42) Chapter 2. Pos. A35. INSTRUMENTS AND CONTROLS. 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. No function has been allocated to this key. Toggle switch,LH tow point. Toggle switch for altering the paving thickness on the LH side. The tow point can only be manually adjusted when the toggle switch (A35) for the levelling system has been moved to the MAN mode. Move the switch to the rear (upwards): Increase the mat thickness Centre Position: neutral Move the switch to the front (downwards): Reduce the mat thickness. 2-18. Track Paver Titan 225/325.

(43) INSTRUMENTS AND CONTROLS. 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. Track Paver Titan 225/325. 2-19.

(44) Chapter 2. INSTRUMENTS AND CONTROLS. EXTERNAL CONTROL PANELS The external control panels are mounted mirror inverted at the rear of the paver on the LH and RH sides. Illustration 6:. Table 6: Pos. B1. Illustration. Description Button switch, Increase mat thickness. Function Increase the angle of attack on the LH and RH side of the screed to increase the mat thickness. Ensure the tow points are not adjusted to opposite limit stops (one tow point to the upper and one tow point to the lower limit stop). This will cause undue torsion and twisting on the screed. The maximum permissible difference in height between the LH & RH mat thickness scales must not exceed 100 mm. Never operate the tow point adjustment when the screed is raised and secured in the transport locks otherwise damage will occur to the locking device.. 2-20. Track Paver Titan 225/325.

(45) INSTRUMENTS AND CONTROLS. Pos.. Illustration. Chapter 2. Description. Function. B2. Button switch, Reduce the mat thickness. Reduce the angle of attack on the LH and RH side of the screed to reduce the mat thickness. Refer to B1.. B3. Button switch,overmodulating the augers. For overmodulating the RH respectively the LH auger. Use the overmodulating function if you require a higher head of material in the auger channel for a short time (e.g. just before extending the Vario screed). The respective auger will rotate at maximum speed as long as you keep the button switch depressed. Condition: Pressure switch B7 is pulled upwards.. B4. Button switch,Vario screed extend. Extend the LH / RH Vario screed.The warning light B8 will flash when the Vario screed is extended.. B5. Button switch, Vario screed retract. Retract the LH / RH Vario screed. The warning light B8 will flash when the Vario screed is extended.. B6. Button switch, warning horn. Press the button to sound the warning horn.. B7. Pressure switch STOP material flow. The material flow (conveyors and augers) can be stopped separately on both sides if the head of material in the auger channel is too high. Released: Normal operation Depressed: LH respectively RH conveyor and auger will be stopped.. B8. Track Paver Titan 225/325. Warning light Vario screed extend / retract. Flashes when the Vario screed is extended or retracted.. 2-21.

(46) Chapter 2. INSTRUMENTS AND CONTROLS. STORAGE COMPARTMENTS Illustration 7:. Table 7: Pos.. 2-22. Description. Location. 1. Tool box tray. Underneath the deck plate on the operator's platform. 2. Compartment for First aid box and operating manual. RH side on the operator's platform. Track Paver Titan 225/325.

(47) INSTRUMENTS AND CONTROLS. Chapter 2. FUEL TANK Illustration 8:. Table 8: Pos. 1. Description Filler cap. Track Paver Titan 225/325. 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.

(48) Chapter 2. INSTRUMENTS AND CONTROLS. CENTRAL LUBRICATION SYSTEM (OPTION) The paver can be equipped with a central lubrication system located inside the RH side door; the system lubricates the paver at specified intervals.. !. CAUTION. Observe the following: •. The central lubrication system functions automatically.Nevertheless, check at regular intervals and ensure that lubricant emerges from the grease points.. •. The grease container must never run empty otherwise the pump must be deareated. Illustration 9. Table 9: Pos.. 2-24. Description. Function. 1. Central lubrication system. Lubricates the basic auger, conveyor drive shaft and conveyor idler shaft as well as the bearing arms. 2. Lubricating point. Connection for the grease gun (4). 3. Pressure relief valve. Safety valve. 4. Grease gun. Filling the grease container with lubricant. Track Paver Titan 225/325.

(49) INSTRUMENTS AND CONTROLS. Chapter 2. MAT THICKNESS SCALES The mat thickness scales show the approximate thickness of the mat being paved. Instructions for mechanically altering the screed's angle of attack as well as for adjusting the mat thickness are included in the operating manual for your paving screed. Illustration 10:. Table 10: Pos. 1. Description Mat thickness scales. Track Paver Titan 225/325. Function Indicates the approx. paving thickness. 2-25.

(50) Chapter 2. INSTRUMENTS AND CONTROLS. EMULSION SPRAYING SYSTEM (OPTION). !. CAUTION. Protect the environment by using a washdown point with a separator for cleaning the paver. If this is not possible on your job-site, then the cleaning solvent must be collected in a suitable container. Do not allow the cleaning solvent to seep into the ground. Fire hazard Do not use flammable cleaning solvents. Only start spraying the cleaning solvent after the burner chambers have cooled down (approx. 10 minutes after switching off the heating system). Illustration 11:. Table 11: Pos.. 2-26. Description. Function. 1. Stop valve. Hose connection with ball cock. 2. Spraying lance. Spraying lance with nozzle. 3. Level indicator. Shows the level of cleaning solvent in the tank. 4. Filler cap. Top up with non-flammable cleaning solvent. Track Paver Titan 225/325.

(51) INSTRUMENTS AND CONTROLS. Chapter 2. POTENTIOMETERS FOR VIBRATORS AND TAMPERS Illustration 12:. Table 12: Pos. 1. Description Potentiometer, vibrators. Function Setting the vibrators Rotate clockwise: reduce the vibrator speed Rotate anti-clockwise: increase the vibrator speed. 2. Potentiometer, Tampers“ (This potentiometer is installed with the standard tampers without variable displacement pump). The potentiometer for the heavy duty tampers is located on the control panel -refer to 210Page, Pos. A8b). Track Paver Titan 225/325. Setting the tampers Rotate clockwise: reduce the tamper speed Rotate anti-clockwise: increase the tamper speed. 2-27.

(52) Chapter 2. INSTRUMENTS AND CONTROLS. SWITCH OFF THE LEVELLING CYLINDERS IN CASE OF BREAKDOWNS. !. CAUTION. Always close both ball cocks on the levelling cylinders on both sides of the paver. If you only switch off the levelling cylinder on one side of the paver, the screed will be subject to excess torsion and will be damaged. Illustration 13:. 2-28. Track Paver Titan 225/325.

(53) INSTRUMENTS AND CONTROLS. 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.. Track Paver Titan 225/325. 2-29.

(54) Chapter 2. INSTRUMENTS AND CONTROLS. SCREED HEATING SYSTEM (OPTION) Paving screeds can be heated by propane gas or Diesel fuel (only for Variomatic screeds) heating systems. The operating instructions for the propane gas or Diesel heating system installed on your particular screed are included in the screed's operating manual. There is a separate operating manual for the temperature controlled gas blower heating system (Thermo-Control). Strictly observe all locally prevailing directives and laws for operating the heating system on your paving screed. Secure the propane gas bottles against toppling over on the paver. Operating instructions for the propane gas or Diesel fuel heating system can be taken from the operating manual for your particular paving screed. The heating gas used should, if possible, be pure propane gas and at ambient temperatures above 10° C should have a maximum butane content of approx. 50%. Heating gases with a higher butane content should not be used because they do not develop sufficient vaporising pressure for the gas burners to operate in a stable manner. At ambient temperatures below + 10° C, the butane content may only amount to max. 30%. Some of the connections on the propane gas heating system have left-handed threads.These can be recognised by a groove in all six surfaces on the union nuts. The paver's scope of supply includes two canvas canopies for the gas bottles. Cover the gas bottles with the canopies as follows: 1. During all paver shut-downs when the ambient temperature is above 10° C. 2. When withdrawing gas for continuous paving work at ambient temperatures above 20° C and the gas bottles are exposed to sun rays. Using the canopies will avoid the gas bottles unduly warming up when exposed to sun rays leading to a high gas pressure in the bottles.. !. DANGER. At the end of paving work, close the valves on the gas bottles, the distributor and on the gas burners. Before transporting the paver, close the valves on the gas bottles, remove the gas hose with pressure reducer and fit the protective caps on the gas bottles.. 2-30. Track Paver Titan 225/325.

(55) INSTRUMENTS AND CONTROLS. Chapter 2. The following procedure must be strictly observed to ensure a burner run-down. Machines equipped with standard gas burners •. before switching off the paver's ignition, ensure that the toggle switch for the standard gas burners is moved to Pos. ON (I) to ensure a burner run-down.. Machines equipped with temperature controlled gas burners (Thermo-Control) •. before switching off the paver's ignition, ensure the operating mode switch is moved to the Pos. „AUTO“ or „MAN“ to ensure a burner run-down. Illustration 14:. Table 14: Pos.. Description. Function. 1. Gas bottle connection. Gas hose with pressure reducer. 2. Gas bottle tensioning belt. Securing the bottle against falling over. Track Paver Titan 225/325. 2-31.

(56) Chapter 2. INSTRUMENTS AND CONTROLS. ELECTRONIC LEVELLING SYSTEM (OPTION) When using an automatic levelling system you will obtain the best possible surface evenness. Using a grade control will require a reference surface (kerbstone, adjacent lane or tensioned levelling wire). We do not recommend using a levelling system for paving a wearing course if the previous binder course is smooth and level. Further information on the application of the optional levelling system is included in a separate instruction manual. Illustration 15. Table 15: Pos.. 2-32. Description. Function. 1. Support, Moba controller. For installing the optional Moba controller. 2. Assembly plate Electronic levelling system. Assembly plate for the optional electronic levelling system. Track Paver Titan 225/325.

(57) INSTRUMENTS AND CONTROLS. 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).. Track Paver Titan 225/325. 2-33.

(58) Chapter 2. INSTRUMENTS AND CONTROLS. WORKING LIGHTS Illustration 17:. Table 17: Pos.. 2-34. Description. Function. 1. Working lights. Illuminating the front and rear working area of the paver. 2. Xenon floodlights (Option). Illuminating the front and rear working area of the paver. 3. Warning beacon (Option). To improve safety in the working area;ON / OFF switch located on the roof strut. 4. Additional Working Lights (Option). For illuminating the auger channel. Track Paver Titan 225/325.

(59) INSTRUMENTS AND CONTROLS. Chapter 2. SOCKETS / FUSES ON THE PAVER'S LH REAR WALL Remarks: Ensure the sockets are closed with the protective caps when not in use. This will avoid moisture and dirt damaging the sockets. Illustration 18:. Table 18: Pos.. Description. Function. 1. 24-V socket. Socket for the levelling system / LH slope controller. 2. 24-V socket. Socket for the working lights or additional working lights. 3. 24-V socket. Socket for the working lights or additional working lights. 4. Fuse box. Fuses F83 to F90 (refer to the allocation of fuses in the switch cabinet on the control column). 5. 24-V socket. Socket for the gas burners on the Variomatic screed - basic width. 6. 24-V socket. Socket for the control cable; the socket must be connected during paving work otherwise the LH auger will not function. Track Paver Titan 225/325. 2-35.

(60) Chapter 2. INSTRUMENTS AND CONTROLS. SOCKETS ON THE PAVER'S RH REAR WALL Remarks: Ensure the sockets are closed with the protective caps when not in use. This will avoid moisture and dirt damaging the sockets. Illustration 19:. Table 19: Pos.. 2-36. Function. FUNCTION. 1. 24-V socket. Socket for the levelling system / LH slope controller. 2. 24-V socket. Socket for the working lights or additional working lights. 3. 24-V socket. Socket for the working lights or additional working lights. 4. 24-V socket. Socket for the control cable; the socket must be connected during paving work otherwise the LH auger will not function. Track Paver Titan 225/325.

(61) INSTRUMENTS AND CONTROLS. Chapter 2. SOCKETS ON THE LH AND RH EXTERNAL CONTROL PANELS Remarks: Ensure the sockets are closed with the protective caps when not in use. This will avoid moisture and dirt damaging the sockets. Illustration 20:. Table 20: Pos.. Function. FUNCTION. 1. 24-V socket. Socket for the control cable; the socket must be connected during paving work otherwise the LH auger will not function. 2. 24-V socket. Socket for the levelling system / LH and/or RH grade control. 3. 24-V socket. Socket for the ultrasonic sensor on the RH auger. Track Paver Titan 225/325. 2-37.

(62) Chapter 2. INSTRUMENTS AND CONTROLS. SWITCH CABINET ON THE OPERATOR'S PLATFORM Remarks: Please note that the switch cabinet may only be opened for short periods to perform any work. This will avoid moisture and dirt damaging the sockets. Illustration 21:. Table 21: Pos.. 2-38. Description. Function. 1. Fuses. Please refer to the overview of fuses (G2) on the inside of the switch cabinet door for the allocation of fuses. 2. Plan of fuses and relays. Allocation of fuses and relays. 3. Toggle switch, emergency control. The paver can be operated in emergency control if a fault occurs in the electronics Top position: Emergency operation Lower position: Normal operation. Track Paver Titan 225/325.

(63) INSTRUMENTS AND CONTROLS. Chapter 2. SWITCH CABINET ON THE PAVER'S REAR WALL Remarks: Please note that the switch cabinet may only be opened for short periods to perform any work. This will avoid moisture and dirt damaging the sockets. Illustration 22:. Table 22: Pos.. Description. Function. 1. Switch cabinet, screed heating. Setting the temperature on the screed heating. 2. Switch cabinet. No operation required. Do not alter the settings! Refer to the circuit diagram for functions.. Track Paver Titan 225/325. 2-39.

(64) Chapter 2. INSTRUMENTS AND CONTROLS. SOCKETS ON THE PAVER'S REAR WALL Remarks: Ensure the sockets are closed with the protective caps when not in use. This will avoid moisture and dirt damaging the sockets. Illustration 23:. Table 23: Pos.. 2-40. Description. Function. 1. Connection, hydraulic crown control. Refer to the documentation for the screed. 2. Socket. Not relevant for operation. Track Paver Titan 225/325.

(65) CHAPTER 3 - OPERATION. Track Paver Titan 225/325. 3-1.

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