C-650-F MANUAL DE OPERACION.pdf

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C-650-F/S

Owner/Operator's

Manual

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C-650-F/S

CYLINDER FINISHER

OPERATOR’S

_MANUAL

MACHINE SERIAL NUMBER:__________________________

ENGINE SERIAL NUMBERS:__________________________

G

GOOMMAACCO O CCoorrppoorraattiioonn FFoorrm m NNoo. . CC--665500--FF//SS--00770055GGCC H

Hiigghhwwaayys s 559 9 & & 171755 PPrriinntteed d iin n USUSAA

IIdda a GGrroovvee, , IIA A 5511444455 CCooppyyrriigghht t 2200005 5 GGOOMMAACCOO Telephon

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C-650-F/S

TO THE CUSTOMER:

TO THE CUSTOMER: ...

...

... 1-4

1-4

GENERAL SAFETY STATEMENTS

GENERAL SAFETY STATEMENTS ...

...

... 1-5

1-5

CHAPTER I—SAFETY SECTION

CHAPTER I—SAFETY SECTION ...

...

... 1-6

1-6

CHAPTER II—CONTROLS AND GAUGES

CHAPTER II—CONTROLS AND GAUGES ...

...

... 2-1

2-1

Section 01—Content of chapter ... 2-1 Section 02—Engine controls and gauges ... 2-1 Section 03—Console controls and gauges ... 2-4 Section 04—Carriage controls ... 2-10 Section 05—Stringline sensor controls ... 2-12 Section 06—Moving the machine ... 2-14

CHAPTER III—ASSEMBLY

CHAPTER III—ASSEMBLY ...

...

... 3-1

3-1

Section 01—Content of chapter ... 3-1 Section 02—Assemble the machine frame ... 3-1 Section 03—Install the optional Powered Transition Adjuster (PTA) ... 3-4 Section 04—Install the stationary jack mounts (standard or slipform mounts) ... 3-6 Section 05—Install self- or power-widening jack rails (C-650-F only) ... 3-7 Section 06—Install the optional power-widening system (C-650-F only) ... 3-8 Section 07—Install the self- or power-widening jack mounts (C-650-F only) ... 3-9 Section 08—Install the grade jacks and bogies ... 3-10 Section 09—Install the tracks. ... 3-11 Section 10—Install the carriage and console. ... 3-12 Section 11—Install the hose reel assembly ... 3-13 Section 12—Install the E-Stop system ... 3-14 Section 13—Install the optional electric cord reel ... 3-15 Section 14—Install the hydraulic hoses ... 3-16 Section 15—Install the undercarriage ... 3-16 Section 16—Check drum rotation ... 3-19 Section 17—Install the standard auger(s) and auger guard ... 3-20 Section 18—Install the carriage drive chains ... 3-21 Section 19—Mount the sensors (C-650-S only) ... 3-21 Section 20—Install the slipforms (C-650-S only) ... 3-24 Section 21—Install the optional Spanit ... 3-26 Section 22—Install the undercarriage shift stops ... 3-28 Section 23—Install the float pan(s) ... 3-29 Section 24—Install the optional pan vibrator ... 3-30 Section 25—Install the optional adjustable auger ... 3-32 Section 26—Install the optional rotary vibrator ... 3-33 Section 27—Install the optional carriage weight ... 3-35 Section 28—Install the transport assembly ... 3-35

CHAPTER IV—SETUP AND OPERATION

CHAPTER IV—SETUP AND OPERATION ...

...

... 4-1

4-1

Section 01—Content of chapter ... 4-1 Section 02—Bogie running surfaces (C-650-F only) ... 4-1 Section 03—Adjusting the height of the drums ... 4-2 Section 04—Installing a drum lowering kit ... 4-3 Section 05—Rigging for lifting and installing on forms or bogie rails ... 4-4 Section 06—Adjust the machine to the stringline (sensor equipped machines only) ... 4-5 Section 07—Square the frame to the slab surface ... 4-6 Section 08—Square up the optional PTA ... 4-7 Section 09—Square the ends of the carriage rails to the slab surface ... 4-9

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C-650-F/S

Section 10—Stringline the carriage rails to the slab profile ... 4-10 Section 11—Adjusting the drum(s) to final grade ... 4-12 Section 12—Setting up the optional adjustable augers ... 4-15 Section 13—Setting up the optional rotary stinger vibrator ... 4-15 Section 14—Setting up the optional pan vibrator ... 4-16 Section 15—Starting a pour ... 4-17 Section 16—Machine operation and finishing procedures ... 4-18 Section 17—Finish troubleshooting ... 4-21 Section 18—Estimating the rate of pour and concrete usage ... 4-22

CHAPTER V—MAINT

CHAPTER V—MAINTENANCE

ENANCE ...

...

... 5-1

5-1

Section 01—Content of chapter ... 5-1 Section 02—Fuels ... 5-1 Section 03—Lubricants ... 5-1 Section 04—4 or 5 hour service ... 5-1 Section 05—10 hour or daily service ... 5-2 Section 06—50 hour or weekly service ... 5-7 Section 07—100 hour service ... 5-11 Section 08—250 hour service ... 5-11 Section 09—500 hour or annual service ... 5-12 Section 10—Adjusting pressures ... 5-13 Section 11—Setting the carriage shift delay cylinder (machines with double-drum and Vib-O-Pac 200

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C-650-F/S

¶034-0001

TO THE CUSTOMER:

¶034-0002

Your new GOMACO C-650-F Finisher was carefully designed and manufactured to give years of dependable service. To keep it running efficiently, read the instructions in this manual thoroughly. It contains detailed descriptions and instructions for the efficient operation and maintenance of your C-650-F. Each section is clearly identified so you can easily find the information that you need. Read the Table of Contents to learn where each section is located. All instructions are recommended procedures only.

¶034-0003

Throughout this manual you will come across “CautionCaution”, “WarningWarning” or “DangerDanger” statements which will be printed in bold type and preceded by the symbols shown below. Be certain to carefully read the message that follows to avoid the possibility of personal injury or machine damage.

D

!

DANGER!

!

¶034-0005

A “DANGER” ST

A “DANGER” STAATEMENT IS TEMENT IS OF UTMOSOF UTMOSTT IMPORTANCE AND SIGNALS SEVERE INJURY OR IMPORTANCE AND SIGNALS SEVERE INJURY OR HIGH PROBABILITY OF DEATH TO THE USER IF HIGH PROBABILITY OF DEATH TO THE USER IF PROPER PRECAUTIONS ARE NOT TAKEN. PROPER PRECAUTIONS ARE NOT TAKEN.

W

WARNING!

!

¶034-0007.5

A “WARNING” STATEMENT INDICATES A A “WARNING” STATEMENT INDICATES A POTENTIAL HAZARD WHICH COULD RESULT IN POTENTIAL HAZARD WHICH COULD RESULT IN SERIOUS PE

SERIOUS PERSONAL INJURSONAL INJURYRY..

C

CAUTION!

!

¶034-0009.5

A “CAUTION” STATEMENT INDICATES A HAZARD A “CAUTION” STATEMENT INDICATES A HAZARD THAT COULD RESULT IN MINOR INJURY, OR THAT COULD RESULT IN MINOR INJURY, OR DAMAGE TO EQUIPMENT.

DAMAGE TO EQUIPMENT.

¶034-0010.5

Notice: You will come across

Notice: You will come across “Notice” statements“Notice” statements which will

which will be printed be printed like this like this paragraph. paragraph. AA “Notice” statement explains a

“Notice” statement explains a precaution orprecaution or procedure to be taken

procedure to be taken to prevent personal injury,to prevent personal injury, property damage or an

property damage or an unsatisfactory finishedunsatisfactory finished product.

product.

¶034-0011

Right hand and left hand sides of the machine are determined by facing the direction the C-650-F will travel during paving operations. The auger side of the C-650-F is referred to as the “front” and the float pan is located at the “rear”.

¶034-0013

Record your C-650-F serial numbers in the appropriate spaces provided on the title page. Your GOMACO dealer needs this information to give you prompt, efficient service when you order parts. It pays to rely on an authorized GOMACO Distributor for your service needs. For the location of the Distributor nearest you, contact GOMACO.

¶034-0014

NOTE

NOTE: It is GOMACO’s policy to constantly strive to improve GOMACO products. The information,

specifications, and illustrations in this publication are based on the information in effect at the time of approval for printing and publishing. GOMACO therefore reserves the right to make changes in design and

improvements whenever it is believed the efficiency of the machine will be improved without incurring any obligation to incorporate such improvements in any machine which has been shipped or is in service. It is recommended that users contact an authorized GOMACO Distributor for latest revisions.

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C-650-F/S

¶034-0015

GENERAL SAFETY STATEMENTS

¶034-0016

The C-650-F should only be operated by responsible persons who have thoroughly read the operator’s manual and have been properly instructed to do so. Do not allow unnecessary persons on the machine.

¶034-0017

Be certain all shields and guards are kept in place.

¶034-0018

Use adequate lifting devices while assembling and positioning the C-650-F.

¶034-0019

Keep hands, feet and clothing free of moving parts. Do not wear loose fitting clothing or jewelry that can catch on controls or other parts of the machine.

¶034-0021

Be certain that the engine are shut off before performing service or maintenance on the C-650-F.

¶034-0022.5

Stop the drum(s) and shut the engine off before making any adjustments to the carriage.

¶034-0023

Use care and adequate blocking material when adjusting the height of the machine to prevent injury.

¶034-0024

Wear a hard hat, protective glasses and other protective equipment as required by job conditions.

¶034-0025

Report all needed repairs.

¶034-0026

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C-650-F/S

¶034-0027

CHAPTER I—SAFETY SECTION

¶034-0028

The safety section lists basic safety precautions. In addition, this section identifies the text and locations of warning labels used on the machine.

¶034-0029

Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this equipment.

DCAL-058 ENGLISH

NOTICE

DCAL-058 WARNING! WARNING!

DO NOT OPERATE THIS EQUIPMENT DO NOT OPERATE THIS EQUIPMENT UNTIL YOU HAVE READ

UNTIL YOU HAVE READ AND THOROUGHLYAND THOROUGHLY UNDERSTAND THE OPERATORS MANUAL. UNDERSTAND THE OPERATORS MANUAL. FAILURE TO FOLLOW THIS PROCEDURE FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN INJURY OR DEATH. MAY RESULT IN INJURY OR DEATH. DANGER!

DANGER!

DO NOT ALTER OR MODIFY THIS PRODUCT DO NOT ALTER OR MODIFY THIS PRODUCT WITHOUT THE EXPRESS WRITTEN CONSENT WITHOUT THE EXPRESS WRITTEN CONSENT OF THE MANUFACTURER. UNAUTHORIZED OF THE MANUFACTURER. UNAUTHORIZED MODIFICATION MAY RESULT IN SERIOUS MODIFICATION MAY RESULT IN SERIOUS INJURY OR DEATH.

INJURY OR DEATH.

¶034-0029.1

Operating the machine with a defective emergency stop (E-Stop) system can cause severe injury or death. Check the operation of each emergency stop button every day before beginnning operation. Make certain that all emergency stop buttons are pulled out and that the check E-Stop light on the panel is out. Depress each emergency stop button, one at a time. Depressing any one emergency stop button should cause the check E-Stop light on the panel to illuminate and machine functions to stop. If the check E-Stop light does not illuminate and machine functions do not stop after depressing any emergency stop button, check the system for faults and correct before operating the machine.

¶034-0030

WARNING SIGNS AND DECALS WARNING SIGNS AND DECALS

¶034-0031

There are several specific safety signs or decals on your machine. Please take the time to familiarize yourself with the safety signs.

¶034-0032

Make sure that you can read all safety signs. Clean or replace signs if you cannot read the words or see the pictures. When cleaning the labels use a cloth, water, and soap. Do not use solvents, gasoline, etc., to clean safety signs. The use of solvents, gasoline, etc., could loosen the sign’s adhesive and cause the sign to fall off.

¶034-0033

You must replace a label if it is damaged, missing, or cannot be read. If a label is on a part that is replaced,

make sure a new label is installed on the replaced part. Contact your GOMACO dealer for new labels.

¶034-0034

HIGH

HIGH PRESSURE WAPRESSURE WATERTER

¶034-0035

High pressure water can cause personal injury. When using high pressure water for cleaning, wear a protective face shield, protective clothing and protective shoes. Wear eye protection at all times when cleaning the machine. Pressurized water could cause debris and/or water to be blown and result in personal injury. Do not aim the nozzle at any part of the body.

¶034-0036

FLUID LEAKS FLUID LEAKS

¶034-0037

Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death.

¶034-0038

If fluid is injected into your skin, it must be treated by a doctor familiar with this type of injury immediately.

¶034-0039

Do not kink or strike high pressure lines. Do not install kinked or damaged lines, tubes or hoses.

¶034-0040

Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires.

¶034-0041

Inspect all lines, tubes and hoses carefully. Do not use your bare hands to check for leaks. Tighten all connections securely.

¶034-0042

Check for the following:

¶034-0043

• End fittings damaged or leaking.

¶034-0044

• Outer covering chafed or cut and wire reinforcing exposed.

¶034-0045

• Outer covering ballooning locally.

¶034-0046

• Evidence of kinking or crushing of the flexible part of the hose.

¶034-0047

• End fittings displaced.

¶034-0048

BURN PREVENTION BURN PREVENTION

¶034-0049

Do not touch any part of an operating engine. Allow the engine to cool before any repairs are performed on the engine.

¶034-0050

Do not touch any hydraulic tank, valve or hose when at operating temperature. Allow the hydraulic oil to cool before performing any service on the hydraulic circuits.

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C-650-F/S

¶034-0051

Relieve all pressure in oil or fuel systems before any lines, fittings or related items are disconnected or removed.

¶034-0059

BATTERIES BATTERIES

¶034-0060

Battery electrolyte contains acid and can cause injury. Avoid contact with the skin and eyes.

¶034-0061

Wash hands after touching batteries and connectors. Use of gloves is recommended.

¶034-0062

Batteries give off flammable fumes which can explode.

¶034-0063

Do not smoke when observing the battery electrolyte levels.

¶034-0064

Always wear protective glasses when working with batteries.

¶034-0065

FIRE OR EXPLOSION PREVENTION FIRE OR EXPLOSION PREVENTION

¶034-0066

All fuels, most lubricants and some coolant mixtures are flammable.

¶034-0067

Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and gasoline fumes is extremely explosive.

¶034-0068

Do not smoke in areas where batteries are charged, or where flammable materials are stored.

¶034-0069

Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized persons.

¶034-0070

Store all oily rags or other flammable material in a protective container, in a safe place.

¶034-0071

Do not weld or flame cut the frame, pipes or tubes that contain flammable fluids without prior authorization and instruction from GOMACO or a GOMACO authorized dealer. Do not weld on the machine with the battery connected. Disconnect the battery negative (-) ground cable to prevent damage to the electrical system and/or explosion.

¶034-0072

Remove all flammable materials such as fuel, oil and other debris before they accumulate on the engine or other components of the machine.

¶034-0073

Do not expose the engine or hydraulic components to flames if at all possible.

¶034-0074

Have a fire extinguisher available at all times and know how to use it. Inspect and have it serviced as recommended on its instruction plate.

¶034-0075

When starting from an external source (jump starting), always connect the positive (+) jumper cable to the POSITIVE (+) terminal of the battery of the engine to be started.

¶034-0076

To prevent potential sparks from igniting combustible gases produced by some batteries, attach the negative (-) boost ground cable last, to the starter NEGATIVE (-) terminal (if equipped) or to the engine block.

¶034-0077

Clean and tighten all electrical connections. Check daily for loose or frayed electrical wires. Have all loose or frayed electrical wires tightened, repaired or replaced before operating the machine.

¶034-0078

CRUSHING OR CUTTING PREVENTION CRUSHING OR CUTTING PREVENTION

¶034-0079

Support equipment and attachments properly when working beneath them.

¶034-0080

Never attempt adjustments while the engine is running unless otherwise specified in this manual.

¶034-0081

Stay clear of all rotating and moving parts. Guards should be in place whenever maintenance is not being performed.

¶034-0082

Wear protective glasses when striking objects to avoid injury to your eyes.

¶034-0083

Chips or other debris can fly off objects when stuck. Make sure no one can be injured by flying debris before striking any object.

¶034-0087

PREPARING TO START THE MACHINE PREPARING TO START THE MACHINE

¶034-0088.5

Be sure that all protective guards and covers are installed before the machine is started. To help prevent accidents, work carefully around rotating parts.

¶034-0089

Inspect the machine for potential hazards.

¶034-0090

Make sure no one is working on, or close to the machine before starting or moving it.

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C-650-F/S

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C-650-F/S

CHAPTER II—CONTROLS AND GAUGES

CHAPTER II—CONTROLS AND GAUGES ...

...

... 2-1

2-1

Section 01—Content of chapter ... 2-1 Section 02—Engine controls and gauges ... 2-1 Section 03—Console controls and gauges ... 2-4 Section 04—Carriage controls ... 2-10 Section 05—Stringline sensor controls ... 2-12 Section 06—Moving the machine ... 2-14

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C-650-F/S

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C-650-F/S

CHAPTER II—CONTROLS AND

GAUGES

Section 01—Content of chapter

This chapter describes engine, hydraulic, and electrical controls. It also gives the basic operating procedures for the C-650. Read this chapter thoroughly to identify the controls and operations. Only qualified personnel should be allowed to operate the C-650. PayPay particular attention to all safety statements. particular attention to all safety statements.

Section 02—Engine controls and gauges

Notice: To prevent damage to the engine, read and Notice: To prevent damage to the engine, read and understand the engine manual before starting the understand the engine manual before starting the engine. engine. W

WARNING!

!

TO PREVENT SERIOUS INJURY OR DEATH, MAKE TO PREVENT SERIOUS INJURY OR DEATH, MAKE SURE EVERYONE IS AWAY FROM ALL MOVING SURE EVERYONE IS AWAY FROM ALL MOVING P

PARTS BEFORARTS BEFORE STE STARTING THE ENGINE. ARTING THE ENGINE. STASTAYY CLEAR

CLEAR OF ALL OF ALL MOVING PARTS MOVING PARTS WHEN THEWHEN THE ENGINE IS RUNNING.

ENGINE IS RUNNING. STOP STOP THE ENGINE ANDTHE ENGINE AND REMOVE THE MASTER DISCONNECT SWITCH REMOVE THE MASTER DISCONNECT SWITCH KEY BEFORE PERFORMING ANY SERVICE WORK KEY BEFORE PERFORMING ANY SERVICE WORK ON ANY

ON ANY MOVING PMOVING PARTS UNLESS OTHERWISEARTS UNLESS OTHERWISE INSTRUCTED IN

INSTRUCTED IN THIS MANUAL. THIS MANUAL. IF IF THE ENGINE ISTHE ENGINE IS EQUIPPED WITH AN ENGINE

EQUIPPED WITH AN ENGINE HEAHEATER, DO NOTTER, DO NOT USE ETHER. USE ETHER. C

CAUTION!

!

CONTINUOUS EXPOSURE TO ENGINE NOISE CAN CONTINUOUS EXPOSURE TO ENGINE NOISE CAN CAUSE HEARING DAMA

CAUSE HEARING DAMAGE. GE. DO NOT OPERADO NOT OPERATETE MACHINE WITHOUT HEARING PROTECTION. MACHINE WITHOUT HEARING PROTECTION.

016-0054B

Engine start switch and throttle

Engine start switch:

Engine start switch: Turn the key to the “start” position to start the engine. After the engine starts, allow the switch to return to the “on” position. The “on” position supplies electrical power to the electronic controls and the electric fuel solenoid. The “off” position shuts off all electrical power to the electronic controls and shuts off power to the electrical fuel solenoid to stop the engine.

C

CAUTION!

!

TO

TO PREVENT PREVENT DAMAGE DAMAGE TO THE TURBOCHARGER,TO THE TURBOCHARGER, RUN

RUN THE ENGINE THE ENGINE AAT LOW IDLE FOR T LOW IDLE FOR 30 SECONDS30 SECONDS BEFORE SHUTDOWN.

BEFORE SHUTDOWN.

016-0148A

Throttle switch:

Throttle switch: Controls engine speed. Mo ve the throttle switch to the “low” position to start and idle the engine. Mo ve the throttle switch to the “high” position increase engine speed and operate the machine. Release the throttle s witch to stop adjusting engine speed. Allo w the engine to warm up before moving the throttle switch to the “high” position.

Notice: To prevent engine damage, do not increase Notice: To prevent engine damage, do not increase engine speed above 1000 rpm

engine speed above 1000 rpm until the engine oiluntil the engine oil pressure has increased.

pressure has increased. When the When the oil pressureoil pressure has increased, pull the throttle knob completely has increased, pull the throttle knob completely out before paving (the top speed of the engine has out before paving (the top speed of the engine has been factory-set at 2150 rpm). been factory-set at 2150 rpm). W

WARNING!

!

IF THE ENGINE IS EQUIPPED WITH AN ENGINE IF THE ENGINE IS EQUIPPED WITH AN ENGINE HEA

HEATER, DO NOT USE TER, DO NOT USE AERESOL STARTING AIDSAERESOL STARTING AIDS (SUCH AS ETHER).

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C-650-F/S

079-0285B

Engine heater or glow plug switch:

Engine heater or glow plug switch:If the engine is equipped with an engine heater, and the air temperature is below 16º C, place the engine star t switch in the “on” position and hold the engine heater switch in the “on” position for 15 seconds before starting the engine. If the engine does not start, hold the engine heater switch in the “on” position for an additional 10 seconds before attempting to start again. Place the engine heater switch in the “off” position after the engine starts.

If the engine is equipped with glow plugs, place the engine start switch in the “on” position and hold the glow plug switch in the “on” position for 15 seconds before starting the engine.

Notice: To prevent damage to the glow plugs, do Notice: To prevent damage to the glow plugs, do not hold the glow plug switch in the “on” position not hold the glow plug switch in the “on” position for more than 60 seconds.

for more than 60 seconds.

016-0054A

Engine gauges Engine water temperature gauge:

Engine water temperature gauge: Shows the temperature of the engine coolant. Normal operating temperature is approximately 190° to 200° F (88° to 93° C), depending on outside air temperature. If the water temperature rises above 220° F (104° C), locate the cause and correct.

Engine oil pressure gauge:

Engine oil pressure gauge: Shows the engine oil pressure. Minimum operating pressure for the engine

is 30 psi (2.07 bar) at 2150 rpm. Consult the engine operator’s manual for additional instructions. V

Volt molt meter:eter: Shows the electrical system voltage. During normal operation the volt meter should read 14 volts at 2150 rpm.

Notice: If voltage drops below 12 volts slow Notice: If voltage drops below 12 volts slow electri-cal response may occur.

cal response may occur. Locate the cause of loLocate the cause of loww voltage and correct.

voltage and correct. Tachometer and hour meter:

Tachometer and hour meter: Shows engine speed (in revolutions per minute (rpm)) and hours of operation. Normal operating speed is 2150 rpm (maximum throttle).

016-0061

Master disconnect switch:

Master disconnect switch:Prevents the engine from being started during machine service. Place the key switch in the “off” position and remove the key to disconnect the ground side of the electrical system from the negative post of the battery and keep the engine from being started. Replace the key and place it in the “on” position to reconnect the ground side of the electrical system to the negative post of the battery and allow the engine to be started.

C

CAUTION!

!

TO PREVEN

TO PREVENT DAMAGE TT DAMAGE TO THE ELECTRICALO THE ELECTRICAL SYSTEM, ALWAYS DISCONNECT BOTH BATTERY SYSTEM, ALWAYS DISCONNECT BOTH BATTERY CABLES BEFORE WELDING ON

CABLES BEFORE WELDING ON ANY PART OFANY PART OF THE MACHINE.

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C-650-F/S

079-0105A

Air filter

Air filter restriction indicator:restriction indicator: Monitors the condition of the engine air filter. Replace the air filter when the “service when red” window turns red. After replacing the air filter, push in on the button on the bottom of the air filter restriction indicator to reset it.

W

WARNING!

!

TO PREVENT FIRES AND BURN INJURIES, SHUT TO PREVENT FIRES AND BURN INJURIES, SHUT OFF ENGI

OFF ENGINES AND NES AND ALLOW ALLOW THEM TTHEM TO COOLO COOL BEFORE REFUELING

BEFORE REFUELING THE ENGINES. THE ENGINES. DO NOTDO NOT SPILL FUEL

SPILL FUEL WHILE REFUELING. WHILE REFUELING. IF FUEL ISIF FUEL IS SPILLED,

SPILLED, WIPE UP WIPE UP BEFORE STARTING ENGINES.BEFORE STARTING ENGINES. DO NOT

DO NOT OVERFILL FUEL TOVERFILL FUEL TANKS (LEAVE ROOM ANKS (LEAVE ROOM ININ THE T

THE TANK ANK FOR THE FOR THE FUEL TO EXPAND).FUEL TO EXPAND).

016-0053A

Engine fuel filler:

Engine fuel filler: To reduce condensation in the fuel, keep both fuel tanks full of clean fuel (leave some room in the tank for the fuel to expand). Do not use fuel left over from the previous season.

016-0059

Engine oil dipstick:

Engine oil dipstick: Remove the dipstick to check the engine oil level. If the oil level is low, add more through the oil cap until the oil level is to the full level on the dipstick. Check the dipstick after adding oil. Do not overfill. Replace the dipstick and tighten the oil cap securely. C

CAUTION!

!

TO PREVENT

TO PREVENT ENGINE DAMAGE, CHECK THEENGINE DAMAGE, CHECK THE ENGINE OIL

ENGINE OIL LEVEL BEFORE LEVEL BEFORE STSTARTING THEARTING THE ENGINE. ENGINE. W

WARNING!

!

DO NOT REMOVE THE RADIA

DO NOT REMOVE THE RADIATOR CAP UNLESS TOR CAP UNLESS ITIT IS COOL T

IS COOL TO THE O THE TOUCH. TOUCH. BEFORE REMOVINGBEFORE REMOVING THE CAP, PLACE A RAG OVER IT.

THE CAP, PLACE A RAG OVER IT. SLOWLSLOWLY Y TURNTURN THE CAP TO THE FIRST STOP, THEN WAIT UNTIL THE CAP TO THE FIRST STOP, THEN WAIT UNTIL ALL STEAM

ALL STEAM ESCAPES THROUGH THE OVERFLOESCAPES THROUGH THE OVERFLOWW TUBE.

TUBE.

016-0058

Radiator cap:

Radiator cap:When the engine is cold, remove the radiator cap to check or add to the coolant. Check the coolant every day before starting the engine. The coolant level should be no more than 1 inch (25 mm) below the bottom of the filler neck.

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C-650-F/S

C

CAUTION!

!

TO PREVENT

TO PREVENT ENGINE DAMAGE, CHECK THEENGINE DAMAGE, CHECK THE ENGINE COOLANT LEVEL BEFORE STARTING ENGINE COOLANT LEVEL BEFORE STARTING THE ENGINE.

THE ENGINE.

016-0060

Hydraulic oil filler cap:

Hydraulic oil filler cap: Remove to check hydraulic oil level or add hydraulic oil. The oil should be about 2 inches (5 cm) below the top of the tank when the oil is cold. If the hydraulic oil level is low, add hydraulic oil (the correct type is listed in Chapter V—MaintenanceChapter V—Maintenance) until the correct level is reached.

C

CAUTION!

!

TO PR

TO PREVENT DAMAGE TEVENT DAMAGE TO THE HYDRAULICO THE HYDRAULIC SYSTEMS, CHECK THE HYDRAULIC FLUID SYSTEMS, CHECK THE HYDRAULIC FLUID BEFORE STARTING THE ENGINE. BEFORE STARTING THE ENGINE.

016-0056

Hydraulic filter pressure gauge:

Hydraulic filter pressure gauge:Shows the amount of pressure needed to force oil through the main hydraulic filter. When the hydraulic oil is cold, the gauge needle may be in the yellow or red zones. When the hydraulic oil is warm, the gauge needle should be in the green zone. The filter must be changed when the hydraulic oil is warm and the needle is in the yellow or red zones (oil begins to bypass the filter when the needle enters the yellow zone; the filter is totally bypassed when the needle enters the red zone).

016-0057

Hydraulic oil level and temperature gauge: Hydraulic oil level and temperature gauge: Shows the level and temperature of the hydraulic oil. The hydraulic oil should be half way up the gauge when the oil is cold. If the oil level is low, add oil until the level is halfway up the gauge. Use only the proper grade of hydraulic oil.

Notice:

Notice: TTo prevent damage to hydraulic compo-o prevent damage to hydraulic compo-nents, do not operate the machine when the oil nents, do not operate the machine when the oil level is below the gauge.

level is below the gauge.

Normal operating temperature is 140˚ to 180˚ F (60˚ to 82˚ C), depending on the air temperature. If the hydraulic oil temperature rises above 195˚ F (90˚ C), locate the cause of the overheating and correct. Notice: Excessive oil temperature can cause Notice: Excessive oil temperature can cause serious damage to

serious damage to pumps, motors, and otherpumps, motors, and other hydraulic components.

hydraulic components.

Over heated oil can be caused by excessive load on hydraulic circuits, a hot day, restricted air flow through the oil cooler, and/or by a hydraulic circuit that is constantly exceeding relief pressure. Overheating can be corrected by reducing the load on the hydraulic circuits, cleaning the hydraulic oil cooler fins, and/or reducing the load on circuits that are exceeding relief pressure.

Section 03—Console controls and gauges

W

WARNING!

!

A DEFECTIVE EMERGENCY STOP (E-STOP) A DEFECTIVE EMERGENCY STOP (E-STOP) SYSTEM MAY CAUSE SEVERE INJURY OR SYSTEM MAY CAUSE SEVERE INJURY OR DEATH.DEATH. DO NOT OPERATE ANY MACHINE WITH AN DO NOT OPERATE ANY MACHINE WITH AN INOPERATIVE EMERGENCY STOP SYSTEM. INOPERATIVE EMERGENCY STOP SYSTEM. CHECK THE EMERGENCY STOP SYSTEM CHECK THE EMERGENCY STOP SYSTEM EVERYEVERY DAY FOR PROPER WORKING OPERATION. DAY FOR PROPER WORKING OPERATION.

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C-650-F/S

008-0346A

Check Emergency Stop (E-Stop) light: Check Emergency Stop (E-Stop) light:Illuminates whenever the emergency stop (E-Stop) system is activated. The emergency stop system is activated whenever the key switch is turned from the “off” to the “on” positions, whenever any of the E-Stop buttons are pushed in, or whenever any of the E-Stop buttons are disconnected from the E-Stop system.

When the E-Stop system is activated, the carriage and the machine stop moving and the drums, augers, and vibrators stop working.

If the check E-Stop light comes on, immediately make sure all personnel are safe.

098-0045

Emergency Stop (E-Stop) buttons:

Emergency Stop (E-Stop) buttons:If any E-Stop button is pushed in or disconnected, the E-Stop system is activated. When the E-Stop system is activated, the E-Stop light comes on, the machine and carriage stop moving, and the drums, augers, and vibrators also stop working. All E-Stop buttons must be pulled out during normal operation.

If an E-Stop button has been pushed in and the check E-Stop light comes on, immediately make sure all personnel are safe.

W

WARNING!

!

TO PREVENT SERIOUS INJURY OR DEATH, BE TO PREVENT SERIOUS INJURY OR DEATH, BE CERT

CERTAIN THAAIN THAT ALL T ALL CONTROLS ARE CONTROLS ARE IN THE “OFF”IN THE “OFF” OR “NEUTRAL

OR “NEUTRAL” POSITION BEFORE ” POSITION BEFORE RESETTINGRESETTING THE E-STOP SYSTEM.

THE E-STOP SYSTEM. BE CERTBE CERTAIN AIN THATTHAT EVERY

EVERYONE IS ONE IS CLEAR OF THE BOGIES,CLEAR OF THE BOGIES, CARRIAGE, CARRIAGE CHAIN(S), AND CARRI CARRIAGE, CARRIAGE CHAIN(S), AND CARRIAGEAGE COMPONENTS BEFORE RESETTING THE COMPONENTS BEFORE RESETTING THE EMERGENCY STOP SYSTEM.

EMERGENCY STOP SYSTEM.

008-0346B

Emergency Stop (E-Stop) reset switch: Emergency Stop (E-Stop) reset switch: Allows the machine to operate after the emergency stop system has been activated. The emergency stop reset switch must be pushed up to the “reset” position whenever the engine is started or any emergency stop button pushed in or disconnected.

When the check emergency stop light comes on, place all controls in the “neutral” or “off” position and make sure all personnel are safe.

To resume operation, make sure all emergency stop buttons are connected to the machine and pulled out. Place all controls in the “neutral” or “off” position. Push the emergency stop reset switch up to reset the emergency stop system. The check emergency stop light will go out, and the machine will operate normally.

016-0041A

Left and right advance valves

Left advance valve:

Left advance valve:Allows the left side of the machine to move ahead of the right side. If the handle is turned counterclockwise, oil for the right drive bogie

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2-6

C-650-F/S

or track is bypassed back to tank, and the right bogie or track slows down or stops. As the left drive bogie or track advances at normal speed, the left side of the machine moves ahead of the right, turning the machine to the right.

The rate of left-side advance is controlled by how far the left advance and variable travel valves are turned. If the left and right advance control handles are turned completely clockwise, both sides of the machine will travel at the same speed and the machine will move straight ahead.

Right advance valve:

Right advance valve: Allows the right side of the machine to move ahead of the left side. If the handle is turned counterclockwise, oil for the left drive bogie or track is bypassed back to tank, and the bogie or track slows down or stops. As the right drive bogie or track advances at normal speed, the right side of the machine moves ahead of the left, turning the machine to the left.

The rate of right-side advance is controlled by how far the right advance control and variable travel valves are turned. If the left and right advance control handles are turned completely clockwise, both sides of the machine will travel at the same speed and the machine will move straight ahead.

016-0072A

Travel direction valve:

Travel direction valve: Controls the direction of machine travel. When the valve is placed in the “forward” position, the machine will move forward. When the valve is placed in the “reverse” position, the machine will move backwards. When the control valve is placed in the “neutral” position, the machine will not move.

016-0063A

Travel speed valve:

Travel speed valve: Controls the machine travel speed when the travel direction control valve is in “forward” or “reverse.” The machine should always be started or stopped with this valve.

When the travel speed valve is on the “0” position, the machine will not move. As the valve is rotated clockwise (towards higher numbers) the machine will begin to move (provided the advance control valves are turned completely clockwise and the travel directional valve is in the “forward” or “reverse” position). The more the valve is turned clockwise (towards higher numbers), the faster the machine will move.

Turn the black knob on the valve lever clockwise to lock the valve in any position.

016-0062C

Travel/vibrator on/off switch (optional): Travel/vibrator on/off switch (optional):Stops and starts machine travel and optional console vibrators. Place the travel/vibrator on/off switch in the “on” position to move the machine and run the optional console vibrators. Place the travel/vibrator on/off switch in the “off” position to stop machine travel and the optional console vibrators.

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C-650-F/S

W

WARNING!

!

TO PREVENT

TO PREVENT PERSONAL INJPERSONAL INJURYURY, USE THE, USE THE CARRI

CARRIAGE TRAVEL VALAGE TRAVEL VALVE,VE,NOT THE CARRIAGE THE CARRIAGE TRAVEL V

TRAVEL VARIABARIABLE VALLE VALVE VE (LOCATED (LOCATED ON THEON THE CARRIAGE) TO START AND STOP CARRIAGE CARRIAGE) TO START AND STOP CARRIAGE MOVEMENT.

MOVEMENT.

016-0064A

Carriage travel valve:

Carriage travel valve:Turns all carriage operations on or off. Place the carriage travel valve in the “on” position to start carriage operations. Place the carriage travel valve in the “off” position to stop all carriage operations. When the carriage travel valve is in the “off” position, the carriage will stop moving across the machine frame, the drum(s) and auger(s) will stop turning, and any vibrators attached to the carriage will stop operating.

016-0050H

Pressure gauges Carriage pressure

Carriage pressure gauge:gauge: Shows the pressure of the hydraulic oil going out to the carriage. The oil is used to move the carriage along the machine frame and operate the carriage functions (drum(s), augers, vibrators, etc.). Normal operating pressure will vary, depending on concrete slump and the amount of concrete being pushed by the drums and augers. If the carriage is moving freely across the frame, the carriage pressure gauge will show counterbalance pressure (500 psi (34.5 bar). If the carriage stalls, the

main relief will open and the system pressure gauge will read 2350 psi (161.9 bar).

Lift Pressure Gauge (optional):

Lift Pressure Gauge (optional): Monitors the amount of hydraulic pressure available for the optional automatic grade control system. Normal lift pressure is 1600 psi (105 bar).

Notice: If Lift Pressure Drops Below 1000 Psi (69 Notice: If Lift Pressure Drops Below 1000 Psi (69 Bar), Machine Control May Become Slow. Locate Bar), Machine Control May Become Slow. Locate the cause of low pressure and correct.

the cause of low pressure and correct.

016-0062B

Carriage vibrator on/off switch (optional): Carriage vibrator on/off switch (optional):The vibrator on/off switch turns the optional pan or rotary stinger vibrator on or off. Place the switch in the “on” position to start vibrator operation. Place the switch in the “off” position to stop vibrator operation.

016-0062A

Carriage vibrator up/down switch (optional): Carriage vibrator up/down switch (optional):The vibrator up/down switch raises and lowers the optional rotary stinger vibrator. Hold the switch in the “up” position to lift the stinger vibrator. Hold the switch in the “down” position to lower the stinger vibrator.

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C-650-F/S

016-0054C

Console vibrator variable(s) (optional): Console vibrator variable(s) (optional): Control the speed of the optional vibrator(s) connected to the console. Place a console vibrator variable on the “0” position to stop the vibrator in its circuit. Move a console vibrator variable to a higher number to begin operating the vibrator and to increase its speed.

C

CAUTION!

!

TO PREVENT

TO PREVENT MACHINE DAMAGE MACHINE DAMAGE WHEN THEWHEN THE MACHINE IS EQUIPPED WITH ONE OR MORE MACHINE IS EQUIPPED WITH ONE OR MORE OPTIONAL VIBRAT

OPTIONAL VIBRATOR HYDRAULIC OR HYDRAULIC CIRCUITS,CIRCUITS, CONNECT THE VIBRA

CONNECT THE VIBRATOR QUICK TOR QUICK COUPLERSCOUPLERS TOGETHER

TOGETHER AND AND PLACE THE VIBRAPLACE THE VIBRATOR VTOR VARIABLEARIABLE CONTROL VAL

CONTROL VALVE(S) VE(S) IN THE “0” POSITIIN THE “0” POSITIONON WHENEVER THE MACHINE IS USED WITH A WHENEVER THE MACHINE IS USED WITH A VIBRAT

VIBRATOR OR DISCONNECTED.DISCONNECTED.

016-0072B

Transport axle or PTA valve:

Transport axle or PTA valve: Controls the transport axle lift cylinders and the power transition adjuster (the quick couplers from the transport axle or PTA must be connected to the transport axle or PTA valve quick couplers before either can be used).

The transport axle and wheels are lifted up out of the way during paving operations and lowered to the ground when the machine is moved. The PTA raises

and lowers the machine frame so the machine can finish crowns or inverts in the slab.

Hold the transport axle or PTA valve in the “up” position to lift the transport wheels or increase the crown in the machine frame (depending on which quick couplers are connected). Hold the transport axle or PTA valve in the “down” position to lower the transport wheels or decrease the crown in the machine frame (depending on which quick couplers are connected). Release the transport axle or PTA valve to the “neutral” position to lock the transport wheels or machine frame crown in the desired position. To change the height of the crown or the transport axle wheels when the machine is not moving, place the travel directional control valve in the “neutral” position, rotate the variable travel valve in the “increase” direction, and hold the transport axle or PTA valve in the “up” or “down” position. To change the height of the crown or the transport axle wheels while the machine is paving or backing up, hold the transport axle or PTA valve in the “up” or “down” position (the travel speed may decrease slightly while the PTA or the transport axle is being raised or lowered).

008-0373

Transport jack needle valves Transport jack needle valves:

Transport jack needle valves: Regulate hydraulic flow to the lift cylinders in the transport axles. If one of the cylinders is going up or down faster than the other, turn the cylinder’s needle valve clockwise to slow the cylinder speed. When the cylinders have been completely raised or lowered, turn the needle valves completely clockwise to lock the cylinders in position. Notice: to keep the transport wheels up when the Notice: to keep the transport wheels up when the transport axle quick couplers are

transport axle quick couplers are disconnecteddisconnected from the machine, turn the transport jack needle from the machine, turn the transport jack needle valves completely clockwise before the transport valves completely clockwise before the transport axle quick couplers are disconnected.

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C-650-F/S

047-0231A

Grade solenoid valve override buttons: Grade solenoid valve override buttons:Manually control the grade solenoid valves to raise or lower the legs for troubleshooting purposes. If sensor or jog switch will not raise or lower a leg, depress the corresponding button on either side of the solenoid valve for that leg. If the leg moves up or down, the problem is in the electric system. If the leg doesn’t move up or down, the problem is in the hydraulic system.

047-0243A

Steering solenoid valve override buttons: Steering solenoid valve override buttons:Manually control the steering solenoid valves to steer the tracks for troubleshooting purposes. If sensor or jog switch will not steer the tracks, depress the button on the corresponding solenoid valve. If a track slows down and turns the machine, the problem is in the electric system. If a track doesn’t slow down, the problem is in the hydraulic system.

047-0243B

Steering needle valve Steering needle valve:

Steering needle valve:Controls the speed of the steering when the machine is being steered with the sensor or jog switch. Rotate the valve knob counterclockwise to increase steering speed. Rotate the valve knob clockwise to decrease steering speed.

016-0065

Typical pressure relief valve Pressure relief

Pressure relief valves:valves: Set the maximum hydraulic pressure of a hydraulic circuit, relieving pumps from pressure spikes. If the pressure in a circuit is too high, the circuit’s pressure relief valve opens and bypasses hydraulic oil back to the reservoir. If one pressure relief valve opens in one circuit, it does not affect the operation of any other circuit (it will only dump the oil from the stalled circuit). See Chapter V—Chapter V— Maintenance

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C-650-F/S

016-0066A Circuit breaker Circuit breaker:

Circuit breaker: Two self-resetting circuit breakers are installed behind the control console to protect the electrical circuits. If there is a short in a breaker’s electrical circuit, the breaker will click on and off. Find the source of the short and repair.

Section 04—Carriage controls

W

WARNING!

!

A DEFECTIVE EMERGENCY STOP (E-STOP) A DEFECTIVE EMERGENCY STOP (E-STOP) SYSTEM MAY CAUSE SEVERE INJ

SYSTEM MAY CAUSE SEVERE INJURY OR DEATH.URY OR DEATH. DO NOT OPERATE ANY MACHINE WITH AN DO NOT OPERATE ANY MACHINE WITH AN INOPERATIVE EMERGENCY STOP SYSTEM. INOPERATIVE EMERGENCY STOP SYSTEM. CHECK THE EMERGENCY STOP SYSTEM FOR CHECK THE EMERGENCY STOP SYSTEM FOR PROPER WORKING ORDER BEFORE BEGINNING PROPER WORKING ORDER BEFORE BEGINNING P

PAVING OPERAAVING OPERATIONS. TIONS. TO PREVENT SERIOUSTO PREVENT SERIOUS INJURY OR DEATH, BE CERTAIN THAT ALL INJURY OR DEATH, BE CERTAIN THAT ALL CONTROLS

CONTROLS ARE ARE IN THE “OFF” OR “NEUTRALIN THE “OFF” OR “NEUTRAL”” POSITION BEFORE RESETTING THE EMERGENCY POSITION BEFORE RESETTING THE EMERGENCY STOP SYSTEM.

STOP SYSTEM. BE CERTBE CERTAIN AIN THATHAT ALL PERSONST ALL PERSONS ARE CLEAR OF THE BOGIES, CARRIAGE, AND ARE CLEAR OF THE BOGIES, CARRIAGE, AND CARRIAGE COMPONENTS BEFORE RESETTING CARRIAGE COMPONENTS BEFORE RESETTING THE EMERGENCY STOP SYSTEM.

THE EMERGENCY STOP SYSTEM.

008-0421

Carriage Emergency Stop button (optional): Carriage Emergency Stop button (optional):The carriage emergency stop button(s) are connected to

the emergency stop system and stop all machine operations whenever it is pushed in or disconnected (the drum(s), auger(s), vibrator, undercarriage rotation, bogies, and carriage drive will all stop).

To resume operation if any emergency stop button pushed in or disconnected, first make sure all personnel are safe, then place all console and carriage controls in the “off” or “neutral” position. Make sure all emergency stop buttons are pulled out and connected and push the emergency stop reset switch up to the “reset” position to turn off the emergency stop reset light and resume machine operations.

W

WARNING!

!

TO PREVENT

TO PREVENT PERSONAL INJPERSONAL INJURYURY, DO NOT USE, DO NOT USE THE

THE CARRIAGE VCARRIAGE VARIABLE TRAVEL SPEEDARIABLE TRAVEL SPEED CONTROL VALVE TO START AND STOP CARRIAGE CONTROL VALVE TO START AND STOP CARRIAGE MOVEMENT.

MOVEMENT. ALWALWAAYS USE YS USE THE CARRTHE CARRIAGEIAGE TRAVEL VALVE ON THE CONSOLE TO START AND TRAVEL VALVE ON THE CONSOLE TO START AND STOP CARRIAGE MOVEMENT.

STOP CARRIAGE MOVEMENT.

016-0067

Carriage travel speed valve:

Carriage travel speed valve: Controls the speed of the carriage as it moves across the machine frame. When the carriage travel speed valve is placed the “0” position, the carriage will not move when the carriage travel valve on the console is placed in the “on” position. If the carriage variable travel speed control valve is placed on a number greater than “0” (towards the “increase” direction), the carriage will move across the frame when the carriage travel valve on the console is placed in the “on” position. The more the valve is moved in the “increase” direction (towards higher numbers), the faster the carriage will move when the carriage travel valve on the console is placed in the “on” position.

Turn the black knob on the valve lever clockwise to lock the valve in any position.

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C-650-F/S

016-0055

Vibrator remote (optional):

Vibrator remote (optional): The vibrator on/off switch turns the optional pan or rotary stinger vibrator on or off. Place the switch in the “on” position to start vibrator operation. Place the switch in the “off” position to stop vibrator operation.

The vibrator up/down switch raises and lowers the optional rotary stinger vibrator. Hold the switch in the “up” position to lift the stinger vibrator. Hold the switch in the “down” position to lower the stinger vibrator. Release the switch to stop raising or lowering the vibrator.

W

WARNING!

!

TO PREVENT PERSONAL INJURY, DO NOT USE TO PREVENT PERSONAL INJURY, DO NOT USE THE VIB

THE VIBRATRATOR VARIABLE OR VARIABLE CONTROL VALCONTROL VALVE TOVE TO START AND STOP VIBRATOR OPERATION. START AND STOP VIBRATOR OPERATION. ALWAYS USE THE VIBRATOR ON/OFF SWITCH ON ALWAYS USE THE VIBRATOR ON/OFF SWITCH ON THE CONSO

THE CONSOLE OR LE OR CARRIAGE CARRIAGE TO STARTO START ANDT AND STOP VIBRATOR OPERATION.

STOP VIBRATOR OPERATION.

016-0068

Vibrator variable speed valve(s):

Vibrator variable speed valve(s): The vibrator variable speed control valve(s) control the speed of the vibrator(s). When a vibrator variable speed control valve is placed the “0” position, the vibrator in its circuit will not operate. If a vibrator variable speed control valve is placed on a number greater than “0” (rotated clockwise), the vibrator in its circuit will operate. The

more the valve is moved clockwise, or towards higher numbers, the faster the vibrator will operate. Turn the black knob on the valve lever clockwise to lock the valve in any position.

C

CAUTION!

!

TO PREVEN

TO PREVENT MACHINE T MACHINE DAMADAMAGE WHEN THEGE WHEN THE MACHINE IS EQUIPPED WITH ONE OR MORE MACHINE IS EQUIPPED WITH ONE OR MORE OPTIONAL VIBRA

OPTIONAL VIBRATOR HYDRAULIC TOR HYDRAULIC CIRCUITS,CIRCUITS, CONNECT THE VIBRA

CONNECT THE VIBRATOR QUICK TOR QUICK COUPLERSCOUPLERS TOGETHER, PLACE THE VIBRATOR VARIABLE TOGETHER, PLACE THE VIBRATOR VARIABLE CONTROL VAL

CONTROL VALVE(S) VE(S) IN THE “0” POSITIN THE “0” POSITION, ANDION, AND PLACE THE

PLACE THE VIBRAVIBRATOR ON/OFF TOR ON/OFF SWITCH (SWITCH (ON THEON THE CONSOLE

CONSOLE OR THE VIBRAOR THE VIBRATOR REMOTE) ITOR REMOTE) IN THEN THE “OFF” POSITION WHENEVER THE MACHINE IS “OFF” POSITION WHENEVER THE MACHINE IS USED WITH A VIBRATOR DISCONNECTED. USED WITH A VIBRATOR DISCONNECTED.

016-0069A

Solenoid valve overrides (optional): Solenoid valve overrides (optional): Manually control the operation of the optional vibrator on/off and rotary stinger vibrator lift solenoid valves. If the electric coil on a solenoid valve or the wiring to the coil fail, the solenoid valve overrides can be used to operate the vibrator or vibrator lift and to troubleshoot the problem. If an electric control does not operate a hydraulic circuit, but an override does, there is an electrical problem. If the override does not operate a hydraulic circuit, there is a hydraulic problem.

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C-650-F/S

008-0168A

Carriage shift control valve(s):

Carriage shift control valve(s): Automatically shifts the carriage direction and drum angle of attack at each side of the pour. Also turns the optional rotary vibrator mount at the each side of the pour.

008-0418A

Pressure relief valves:

Pressure relief valves: Set the maximum hydraulic pressure of a hydraulic circuit, relieving pumps from pressure spikes. If the pressure in a circuit is too high, the circuit’s pressure relief valve opens and bypasses hydraulic oil back to the reservoir. If one pressure relief valve opens in one circuit, it does not affect the operation of any other circuit (it will only dump the oil from the stalled circuit). See Chapter V—Chapter V— Maintenance

Maintenance to set the pressure relief valves.

Section 05—Stringline sensor controls

Console electronic controls: Console electronic controls:

098-0063

The electronic console controls for the grade and steering consist of on/off switches, jog switches, and indicator lights for the four track legs and the steering. All systems are identical. The following descriptions apply to all systems.

On/off switches:

On/off switches:Switch automatic control of the legs or steering system on or off. Place an on/off switch in the “off” position to turn off automatic control to a track leg or the steering (the sensor will not control the system). Place an on/off switch in the “on” position to turn on automatic control to a track leg or the steering (the sensor will control the system).

Jog switches:

Jog switches: Manually raise or lower each leg or steer the machine to the left or right. Hold a grade jog switch in the up ( ) or down ( ) position to raise or lower a track leg. Hold the steer jog switch in the left ( ) or right ( ) position to turn the machine to the left or right. Release a jog switch to the center position to stop raising or lowering a track leg or steering the machine to the left or right.

Note:

Note: The machine must be moving forward or backward for the steering jog switch to work. The jog switches will raise or lower the legs or steer the tracks if the on/off switch is in either the “on” or “off” positions (if on/off switch is in the “on” position, the sensors will resume control as soon as the jog switches are released).

Indicator lights:

Indicator lights: Light up whenever a sensor or a jog switch sends an up, down, right, or left signal. For example, if the right front grade sensor sends a down signal, the right front grade down light will light up; if

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C-650-F/S

the steering jog switch is moved to the left position, the left steering indicator light will light up. If a sensor sends a signal, the indicator lights will light up if the on/ off switch is in the “on” or the “off” position.

Sensor controls: Sensor controls:

The C-650 uses electronic stringline sensors to control machine grade and steering. For troubleshooting purposes, all sensors are identical. The following descriptions apply to all sensor systems.

079-0320

Grade and steering sensors:

Grade and steering sensors:The grade and steering sensors automatically control the machine elevation (grade) and steering of the legs and tracks. Each of the sensors contains an on/off switch, a set of indicator lights, and a sensitivity screw.

047-0009B

On/off switch:

On/off switch:The on/off switch on each sensor turns the sensor on and off. Place an on/off switch in the “off” position to manually operate the grade or steering system controlled by the sensor. Place an on/off switch in the “on” position to allow the sensor to automatically operate the grade or steering system. The sensor on/off switches have the same function as the on/off switches on the console.

047-0009A

Indicator lights:

Indicator lights:The indicator lights on the sensors light up when the sensor wand moves up or down or right or left along the stringline. For example, if the stringline moves up, the grade wand moves up, and the up ( ) indicator light on the sensor comes on. The sensor indicator lights have the same function as the indicator lights on the console.

047-0009C

Sensitivity screw:

Sensitivity screw:The sensitivity screw controls how far a sensor wand must move before the sensor sends a signal to operate the system. Turn the sensitivity screw clockwise to decrease sensitivity (the sensor wand must move farther before the sensor moves the legs up or down or turns the tracks right or left). Turn the sensitivity screw counterclockwise to increase sensitivity (the sensor wand won’t move as far before the sensor moves the legs up or down or turns the tracks right or left).

Before operating the machine on a stringline for the first time, turn the sensitivity screws on all the sensors completely clockwise, then turn them counterclockwise one third of a turn. When the machine is on the stringline, check the grade and steer sensor operation. If the legs seem to be moving up and down too quickly, or the machine is turning to the right and left while it is moving along a straight stringline, turn the sensitivity screw clockwise on the sensor controlling the system just far enough to stop the grade or steering problem

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C-650-F/S

(the sensitivity screws should be turned

counterclockwise as far as possible without making the legs or the steering unstable.

Section 06—Moving the machine

Pre-Start Checks:

Pre-Start Checks: Check all oil and coolant levels and perform all necessary maintenance the machine before starting engine. See Chapter IV—Chapter IV— Maintenance

Maintenance for a complete listing of all maintenance procedures.

Before starting the engine, place all controls in the neutral or “off” position. Place all sensor control switches in the “off” position.

C

CAUTION!

!

CONTINUOUS EXPOSURE TO ENGINE NOISE CAN CONTINUOUS EXPOSURE TO ENGINE NOISE CAN CAUSE HEARING DAMA

CAUSE HEARING DAMAGE. GE. DO NOT OPERADO NOT OPERATETE MACHINE WITHOUT HEARING PROTECTION. MACHINE WITHOUT HEARING PROTECTION.

W

WARNING!

!

TO PREVENT SERIOUS INJURY

TO PREVENT SERIOUS INJURY OR DEAOR DEATH. TH. MAKEMAKE SURE EVERYONE IS AWAY FROM THE MACHINE SURE EVERYONE IS AWAY FROM THE MACHINE AND

AND ALL MOVING ALL MOVING PPARTS BEFORE ARTS BEFORE STSTARTING THEARTING THE ENGINE.

ENGINE. THE OPERATHE OPERATOR MUST REMAIN ON THETOR MUST REMAIN ON THE OPERAT

OPERATORS ORS PLAPLATFORM WHILE THE ENGITFORM WHILE THE ENGINE INE ISS RUNNING.

RUNNING. PLACE ALL CONTROLS PLACE ALL CONTROLS IN IN THE "OFF"THE "OFF" OR "NEUTRAL" POSITION AND SHUT OFF THE OR "NEUTRAL" POSITION AND SHUT OFF THE ENGINE BEFORE DISMOUNTING THE MACHINE. ENGINE BEFORE DISMOUNTING THE MACHINE. Turn the ignition key to the “start” position until the engine starts. Release the key and allow it to return to the “on” position. After the engine starts, do not increase engine speed above 1000 rpm for one minute to allow engine oil pressure to increase. Increase the engine speed to 1500 rpm and allow the engine to warm-up for 3 to 5 minutes.

If the air temperature is below 60º F (16º C), place the engine start switch in the “on” position and hold the engine heater or glow plug switch in the “on” position for 15 seconds before starting the engine (the engine heater light will come on when the engine heater switch is in the “on” position). If the engine does not start, place the engine switch in the “on” position for an additional 10 seconds before attempting to start again. Place the engine heater switch in the “off” position after the engine starts.

Notice: Do not operate the starter

Notice: Do not operate the starter longer than 30longer than 30 seconds at a time or

seconds at a time or damage may result to thedamage may result to the star

starter. ter. Allow the starter to cool Allow the starter to cool for 2 for 2 or 3 minutesor 3 minutes between starting attempts.

between starting attempts.

W

WARNING!

!

TO PREVENT SERIOUS INJURY OR DEATH BE TO PREVENT SERIOUS INJURY OR DEATH BE CERT

CERTAIN THAAIN THAT THE T THE AREA AREA AROUND THE AROUND THE MACHINEMACHINE AND THE

AND THE TRACKS IS CLEAR TRACKS IS CLEAR BEFORE MOVING ORBEFORE MOVING OR TURNI

TURNING NG THE MACHINE. THE MACHINE. MOVE SLOWLMOVE SLOWLY Y WHILEWHILE LOADING OR UNLOADING THE MACHINE OR LOADING OR UNLOADING THE MACHINE OR WHEN TRA

WHEN TRAVELING VELING DOWN EMBANKMENTS.DOWN EMBANKMENTS. To move the C-650, increase the engine speed to maximum. Use the grade jacks or grade jog switches to raise the machine high enough to clear any obstacles.

Place the track directional valve in the “forward” or “reverse” position. To start moving the machine, slowly rotate the travel speed valve clockwise. To steer the machine, rotate the left or right advance valves, or place the steer on/off switch in the “on” position and move the “jog” switch on the steering control panel to the left ( ) or right ( ) position as needed.

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C-650-F/S

CHAPTER III—ASSEMBLY

CHAPTER III—ASSEMBLY ...

...

... 3-1

3-1

Section 01—Content of chapter ... 3-1 Section 02—Assemble the machine frame ... 3-1 Section 03—Install the optional Powered Transition Adjuster (PTA) ... 3-4 Section 04—Install the stationary jack mounts (standard or slipform mounts) ... 3-6 Section 05—Install self- or power-widening jack rails (C-650-F only) ... 3-7 Section 06—Install the optional power-widening system (C-650-F only) ... 3-8 Section 07—Install the self- or power-widening jack mounts (C-650-F only) ... 3-9 Section 08—Install the grade jacks and bogies ... 3-10 Section 09—Install the tracks. ... 3-11 Section 10—Install the carriage and console. ... 3-12 Section 11—Install the hose reel assembly ... 3-13 Section 12—Install the E-Stop system ... 3-14 Section 13—Install the optional electric cord reel ... 3-15 Section 14—Install the hydraulic hoses ... 3-16 Section 15—Install the undercarriage ... 3-16 Section 16—Check drum rotation ... 3-19 Section 17—Install the standard auger(s) and auger guard ... 3-20 Section 18—Install the carriage drive chains ... 3-21 Section 19—Mount the sensors (C-650-S only) ... 3-21 Section 20—Install the slipforms (C-650-S only) ... 3-24 Section 21—Install the optional Spanit ... 3-26 Section 22—Install the undercarriage shift stops ... 3-28 Section 23—Install the float pan(s) ... 3-29 Section 24—Install the optional pan vibrator ... 3-30 Section 25—Install the optional adjustable auger ... 3-32 Section 26—Install the optional rotary vibrator ... 3-33 Section 27—Install the optional carriage weight ... 3-35

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C-650-F/S

CHAPTER III—ASSEMBLY

Section 01—Content of chapter

This chapter contains instructions for the assembly of the C-650. Also covered are the instructions for mounting the attachments to the machine. All adjustments are recommended procedures only. Read this chapter thoroughly to identify yourself with your particular machine. Pay particular attention toPay particular attention to all safety statements.

all safety statements.

Section 02—Assemble the machine frame

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WARNING!

!

NEVERUSE FINGERS TO CHECK ALIGNMENT OFUSE FINGERS TO CHECK ALIGNMENT OF BOL

BOLT HOLES. T HOLES. WHEN PWHEN PARTS OR ARTS OR THE MACHINETHE MACHINE SHIFTS YOUR FINGERS MAY BE AMPUTATED. SHIFTS YOUR FINGERS MAY BE AMPUTATED. ALW

ALWAAYS USE YS USE AN ALIGNAN ALIGNMENT PIN TO LINE UMENT PIN TO LINE UPP BOLT HOLES.

BOLT HOLES.

Choose a level working area to assemble the C-650. The machine may be assembled at the job site and run over the slab under its own power, or it may be lifted into place with a crane or other suitable lifting device.

Before laying out the component parts for assembly, take the following factors into consideration: 1. Overall width of the Overall width of the machine:machine: For square pours

(where the machine frame is perpendicular to the bogie rails or forms), the machine should be at least 5 feet (1.5 m) wider than the width between the slab forms or bogie rails on which the bogies will travel (for example, if the slab will be 20 feet (6.1 m) wide, the 650 frame must be at least 25 feet (7 m) wide).

2. Direction of pour:Direction of pour:Decide what direction the machine will move when it is operated. The front of the machine will face the paving operation. The left and right ends will be determined by standing behind the machine and looking in the paving direction.

3. Console position:Console position: The console can be installed on either end of the machine with the controls facing towards the end of the machine.

For machines equipped with a single-drum undercarriage, the console should be on the end of the machine that allows the operator to see the finish pass of the drum, and on the same end of the machine as the stationary jacks (C-650-F only). The console should also be on the high side of a

super-elevation and on the opposite side of the crane or the concrete pump.

4. PTPTA A location:location: The optional PTA assembly may be installed between any of the standard pin-connected frame sections. Several PTA assemblies can also be installed. Plan to position PTA joints over the crown(s) or invert(s) in the slab. If the machine is not equipped with a PTA, but the slab will be poured with a crown or an invert, assemble the frame so that a pin-connect joint is above the crown or invert.

Assemble the main frame:

Assemble the main frame:The directions below describe frame assembly starting from the end of the machine opposite the console. Lay out all components—frame panels, jacks, and console—on the correct sides of the machine.

Lay out the frame panels male-to-female accordingly. Place the panels so that they can be easily assembled with the carriage rail on the inside and at the bottom of the assembled frame.

Note:

Note: If a 2 foot (.6 m) frame section will be used, it should be installed on one end of the machine or the other unless otherwise specified by the machine design.

008-0115

Starting at the end of the frame opposite of the console, lift up the end panel so that its pin connectors are on the bottom.

Lift a frame panel so that its male to female pin connectors are on the bottom and facing towards the lifted end panel (if the machine is a C-650-F, and is equipped with self-widening panels, attach it to the end panel).

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3-2

C-650-F/S

008-0112

Bring the male and female pin connectors on the end panel and self-widening panel together and insert a tapered pin. Secure the tapered pin with a hair pin. Lift the another matching panel and connect it with a tapered pin and hair pin to the end panel.

008-0244

Attach the top of the end panel to the tops of the self-widening panels with5_⁄₈_{inch x 2 inch (16 x 51 mm)}

bolts, flat washers, lock washers, and nuts. Install the flat washers on the slotted hole sides of the bolts. Tighten both nuts securely.

008-0245A

Place two sway braces diagonally across the top of the self-widening panels in the shape of an “X” so the

holes in the ends of the braces line up with the holes in the top of the self-widening panels.

047-0306

Insert the pins on a cross arm down through the sway braces and into the holes in the top of the frame section.

008-0066

Hose holder installed on rear of frame Push the cross arm down until a picker pin can be inserted through the holes in the frame tube and both cross arm pins. On the front of the frame, place a flat washer on the picker pin and secure the pin with a cotter pin. On the rear of the frame, place a hose holder and flat washer on the picker pin and secure with a cotter pin (install hose holders on the rear of the frame only).

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WARNING!

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TO PREVENT FRAME DAMAGE AND SERIOUS TO PREVENT FRAME DAMAGE AND SERIOUS INJURY

INJURY, INSTALL TWO PICKER , INSTALL TWO PICKER PINS THROUGHPINS THROUGH ALL CROSS ARMS.

ALL CROSS ARMS.

Place the next pair of sway braces diagonally across the top of the frame and align their holes with those in the first pair of sway braces and the top of the frame. Install a cross arm, picker pins, hose holders (on the rear of the frame), washers, and cotter pins. Repeat to install sway braces and cross arms in the remaining holes in the frame panels.