Vogele AP-13 Operating Instruction

VOGELE

JOSEPH VOGELE AG

Neckarauer Strasse 168-228 D-68146 Mannheim Germany

Telephone:+49 (0) Fax:

+49

(0)

621 8 10 621 8 10

OPERATING INSTRUCTIONS

5-0

5-466

SUPER

1600-2/1800-2

11.82

Series

15.06.2006

Issue

date

2063675

Catalogue

02

order

EN

number

Joseph

Vogele

AG

WIRIGEN

~-

v

•·

TABLE OF CONTENTS

TABLE

OF

CONTENTS

TABLE

1

1.00

1.00.01

1.00.02

1.00.03

1.00.04

1.01

1.02

1.02.01

1.02.02

1.02.03

1.03

1.04

1.05

1.06

OF

CONTENTS ..................................................................................................

.!

General ............................................................................................................... 9

Introduction .................................................................................................................................... 9

Changes

Packaging and storage .........................................................................................................

Markers and symbols used

Safety marker ........................................................................................................................ 12

Documentation ............................................................................................................................. 14

Usage ........................................................................................................................................... 15

Correct use ........................................................................................................................... 15

Reasonably foreseeable incorrect use ................................................................................. 15

Residual hazards .................................................................................................................. 16

Protection

Disposal ....................................................................................................................................... 17

Declaration of conformity ............................................................................................................. 18

Type plate .................................................................................................................................... 19

I rights reserved ..................................................................................................... 1 0

in

these instructions .................................................................

of

the environment ...................................................................................................... 17

11 11

1.07

1.07.01

1.07.02

1.07.03

1.08

1.09

1.09.01

1.10

1.10.01

1.10.02

1.11

1.11.01

1.12

1.12.01

1.12.02

1.12.03

2

Noise and vibration figures .......................................................................................................... 20

Sound power level ................................................................................................................. 20

Sound pressure level ............................................................................................................ 20

Vibration information for the operator ................................................................................... 20

Technical data ..............................................................................................................................

Personnel- qualifications and obligations ....................................................................................

Personal safety equipment ................................................................................................... 23

General

Hazard area .................................................................................................................................

Labelling ....................................................................................................................................... 28

safety

instructions

Safety manual ....................................................................................................................... 24

Instructions

Safety distance between working area and road traffic ........................................................ 27

Labelling diagram .................................................................................................................. 28

Labels used ...........................................................................................................................

Labels used - USA version .................................................................................................. 33

on

electrical/electronic components ................................................................. .24

..........................................................................................................

21 21

24

26

28

Description/operation ..................................................................................... 39

by

Joseph Vogele AG

BAL_1182_2063675_02_EN.doc

2.00.12

TABLE

Not

used ............................................................................................................................. 147

OF

CONTENTS

2.00.13

2.00.13.01

2.00.13.02

2.00.13.03

2.00.14

2.00.14.01

2.00.14.02

2.00.14.03

2.00.14.04

2.00.14.05

2.00.15

2.00.16

2.00.16.01

2.00.16.02

2.00.16.03

2.00.16.04

2.00.16.05

2.00.16.06

2.00.16.07

2.00.16.08

2.00.16.09

2.00.16.10

Cleaning system (option) ................................................................................................... 148

Cleaning system Hose

drum

with

release agent tank ......................................................................................... 148

........................................................................................................................................ 150

Shoulder spray ................................................................................................................................. 150

Screed attachment. ............................................................................................................ 151

Tow point

Screed assist (option) .......................................................................................................................

ram

................................................................................................................................... 153

154

Screed mechanical locking ............................................................................................................... 155

Electrical Tow point

Not Spray module (only

Emulsion tank ...................................................................................................................................

Heating .............................................................................................................................................

and

hydraulic

arm

adjustment ................................................................................................................ 157

road

paver I

screed

connection ................................................................... 156

used ............................................................................................................................. 157

SUPER

1800-2 SprayJet) .................................................................. 158

160

161

Tanker fitting ..................................................................................................................................... 162

Emulsion Spray

pump

................................................................................................................................. 164

bars

........................................................................................................................................

166

Fittings .............................................................................................................................................. 167

Spray

module

Cleaning

operator's console ..................................................................................................... 168

system

............................................................................................................................... 179

Hand-held spray lance ...................................................................................................................... 180

Labelling ...........................................................................................................................................

181

2.00.17

2.00.18

2.00.19

2.01

2.01.01

2.01.02

2.01.03

2.01.04

2.01.05

2.01.05.01

2.01.06

2.01.07

2.01.07.01

2.01.07.02

2.01.07.03

2.01.08

2.01.09

2.01.09.01

2.01.09.02

2.01.09.03

Compressed air system (only

SUPER

1800-2 SprayJet) .................................................. 182

Central lubricating system ................................................................................................. 183

Screed ................................................................................................................................ 183

Operation ................................................................................................................................... 184

Placing road paver in operation ......................................................................................... 185

Driving, stopping and turning road paver ........................................................................... 188

Laying pavement. ............................................................................................................... 189

Automatic steering

system-

mechanical sensing (option) ................................................ 190

Manoeuvring road paver .................................................................................................... 192

Raising/lowering

and

mechanically locking

screed

........................................................................... 193

Cleaning and shutting down road paver ............................................................................ 195

Transporting

Locking hopper walls ........................................................................................................................

I loading road paver ...................................................................................... 198

201

Folding roof ....................................................................................................................................... 202

Moving

Towing road paver .............................................................................................................

Operating Niveltronic® components (option) ......................................................................

Road

Laser receiver ...................................................................................................................................

Big

awning

(option) .................................................................................................................... 203

scanner ................................................................................................................................... 206

ski

............................................................................................................................................... 213

204 206

211

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

Ill

TABLE OF CONTENTS

3.08.01

3.08.02

3.08.02.01

3.08.02.02

3.09

3.10

3.10.01

3.10.02

3.10.03

3.1

0.03.01

3.10.03.02

3.10.03.03

3.10.03.04

3.10.04

3.10.04.01

3.10.04.02

3.10.04.03

3.11

3.12

Crawler track ...................................................................................................................... 261

Traction drive ..................................................................................................................... 264

Changing gearbox Replacing

feed

oil

........................................................................................................................ 264

pump

oil

filter ........................................................................................................... 266

Steering system ......................................................................................................................... 267

Material transport ....................................................................................................................... 267

Push roller .......................................................................................................................... 267

Material hopper/entry flap .................................................................................................. 267

Conveyors .......................................................................................................................... 268

Tensioning conveyor Tensioning drive Changing

gearbox

chain

............................................................................................................... 268

chain

......................................................................................................................

oil

........................................................................................................................ 273

272

Clean conveyors ............................................................................................................................... 27 4

Distribution augers ............................................................................................................. 275

chain

Tensioning drive Changing gearbox

...................................................................................................................... 276

oil

........................................................................................................................ 277

Clean distribution augers .................................................................................................................. 278

Grade and slope unit. ................................................................................................................. 279

Not

used ..................................................................................................................................... 279

3.13

3.13.01

3.13.02

3.14

3.15

3.16

3.16.01

3.16.01.01

3.16.02

3.16.02.01

3.16.03

3.17

3.17.01

3.18

3.19

4

4.00

Cleaning system ......................................................................................................................... 279

Cleaning filter screen ......................................................................................................... 279

Changing filter cartridge ..................................................................................................... 280

Screed attachment .....................................................................................................................

Not

used ..................................................................................................................................... 281

Spray module (only

SUPER

1800-2 SprayJet) .......................................................................... 282

281

Emulsion pump .................................................................................................................. 282

Changing filter ..................................................................................................................................

282

Spray module operator's console ...................................................................................... 284

Change

air filter ................................................................................................................................

284

Spray nozzle test ............................................................................................................... 286

Compressed air system (only

SUPER

1800-2 SprayJet) .......................................................... 288

Changing air drier filter cartridge ....................................................................................... 288

Central lubricating system .......................................................................................................... 289

Screed ........................................................................................................................................ 290

Tables .............................................................................................................

Technical data ............................................................................................................................

291

4.00.01

4.00.02

Weights ..............................................................................................................................

Operation ........................................................................................................................... 292

by

Joseph Vogele AG

BAL_1182_2063675_02_EN.doc

291

v

W!RTGEN

GROIJI'

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~

.•

TABLE OF CONTENTS

5.05.01.02

5.05.01.03

5.05.02

5.05.02.01

5.05.02.02

5.05.03

5.05.04

5.05.04.01

5.05.04.02

5.05.04.03

5.05.04.04

5.05.04.05

5.05.04.06

5.05.04.07

5.06

5.07

5.07.01

5.07.02

5.07.02.01

5.07.02.02

5.07.02.03

5.07.02.04

5.07.02.05

5.07.02.06

5.07.02.07

Auger

extension size 0.65 m ............................................................................................................

Auger

extension size 1.2 m .............................................................................................................. 346

Overview

Auger Auger

of

auger extensions available ............................................................................ 347

extension extension for 4.6

for

4.6

m ................................................................................................................ 347

to

7.1

m ....................................................................................................... 348

345

Sliding pipe with bracing .................................................................................................... 349

Working widths ................................................................................................................... 350

Working width

Working width 5.0 to 6.5 m ...............................................................................................................

Working width 6.0 to 7.5 m ............................................................................................................... 352

Working width 7.0 to 8.5 m ............................................................................................................... 353

Working width 7.5 to 9.0 m ............................................................................................................... 354

Working width 8.5 to 10.0 m .............................................................................................................

Working width 9.5 to 1 0 m ................................................................................................................ 356

4.0

to 5.5 m ............................................................................................................... 350

351

355

Fitting, adjusting and locking steering system ........................................................................... 357

Spray module (only SUPER 1800-2 SprayJet) .......................................................................... 359

Fitting spray nozzles .......................................................................................................... 359

Fitting the spray module ..................................................................................................... 360

Removing components for conversion ............................................................................................. 360

Fitting socktes ................................................................................................................................... 362

Fitting spray bars .............................................................................................................................. 364

Fitting spray module ......................................................................................................................... 368

Connecting cables ............................................................................................................................ 370

Connecting the lighting ..................................................................................................................... 372

Mounting hand rails and screed rail .................................................................................................. 373

5.07.03

5.07.04

Removing the spray module .............................................................................................. 37 4

Paving without spray module ............................................................................................. 375

CHANGES ................................................................................................................... 377

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

VII

~

W!RTGEN

GROIJI'

"'-J

General

Introduction

1

1.00

GENERAL

Introduction

In

this section you, as the operator, will find important instructions on the

operation

CD

This VOGELE machine is a product from the wide range construction machinery.

The extensive experience test methods guarantee the very high reliability operating instructions belong with the machine!

These operating instructions are only valid safety manual. Please note:

These operating instructions were written for the operator and the maintenance engineer on the construction site.

These operating instructions are intended to place these people position to be able to operate the machine safely and to use its features to the full.

They also provide instructions on the function of important attachments and systems.

of

the machine and the use

of

VOGELE as well as the latest production and

of

these operating instructions.

of

VQGELE road

of

your machine. The

in

conjunction with the

in

the

Specific terms are used misunderstandings, you should always use the same terms.

Only qualified, instructed and trained personnel are allowed to work on this machine.

The operating instructions, the safety manual and the stipulations and regulations applicable accident prevention regulations).

The use of these operating instructions will make it easier for you:

• To familiarise yourself with the machine.

• To avoid malfunctions due to incorrect operation.

Observing the operating instructions:

• Will help to prevent hazards.

• Will increase reliability

• Will increase the service life

• Will reduce maintenance costs and downtimes.

Always keep these operating instructions at hand, for example machine's toolbox or

Should you receive further information on the machine from us, these instructions are also to be observed and attached to the operating instructions (for example additional technical information).

in

these operating instructions. To avoid

in

the place

in

the holder provided.

of

use must be observed (for example

use on the construction site.

of

the machine.

in

the

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

9

General

Introduction

1.00.02

1.00.03

Packaging and storage

To ensure adequate protection during shipment, the products have been carefully packed. On receipt should be checked for damage.

In

the case operation. Damaged cables and connectors are a safety risk and must not be used under any circumstances.

VOGELE supplier.

If the machines are not placed in operation immediately after unpacking, they must be protected against moisture and dirt.

of

damage, the machines are not allowed to be placed

Markers and symbols used

The markers and symbols use the instructions and the machine quickly and safely.

Advanced Organizer

The Advanced Organizer provides you with a brief introduction to the

CIJ

NOTE NOTE

contents

The notes provide you with information practical utilisation

of

the section that follows.

of

the goods, the packaging and the goods

In

this case please contact your

in

these instructions

in

these instructions are intended to help you to

on

the most effective and most

of

the machine and these instructions

in

> Actions

of

The defined sequence and safely use the machine .

../ Result

Here you will find a description

on

(1) Item number

Item numbers brackets().

[1]

Item number

Item numbers on illustrations of specific parts are marked square brackets[].

assembly illustration

on

general illustrations are marked

on

individual part illustration

actions will make it easier for you to correctly

of

the result of a sequence of actions.

in

the text with round

in

the text with

©

2008

by Joseph Vogele

AG

BAL_1182_2063675_02_EN.doc

11

General

Introduction

Warning of hot surface

This warning marker is given before activities during which there are

risks due to hot surfaces.

Warning of batteries

This warning marker is given before activities during which there are

risks due to a corrosive liquid.

Warning of inflammable substances

This warning marker is used before activities during which there are

risks due to inflammable substances, possibly with fatal consequences.

Warning of potentially explosive substances

This warning marker is used before activities during which there are

risks due to potentially explosive substances, possibly with fatal

consequences.

Warning of toxic substances

This warning marker is used before activities during which there are

risks due to toxic substances, possibly with fatal consequences.

BAL_1182_2063675_02_EN.doc 13

WIRTGEN

GROUP

'-.:__/

~-

.,

1.02 Usage

1.02.01 Correct use

General

Usage

The machine is state regulations at the time it was placed correct use.

It was not possible to prevent foreseeable misuse or residual hazards by

design means without restricting correct functionality.

The machine is designed:

• For paving, compacting and smoothing construction materials used

layers for road surfaces.

• For paving thin wearing courses by hot laying (only SUPER 1800-2

SprayJet).

• For applying binders.

The machine is only intended for industrial use sites.

The machine must be operated by trained operators the requirements

Any incorrect use and all activities on the machine that are not described

in

these instructions represent unauthorised misuse beyond the bounds

the manufacturer's liability.

of

the art and complies with the applicable safety

on

the market

in

the technical documentation.

in

the context

on

closed construction

in

accordance with

of

its

in

of

1.02.02 Reasonably foreseeable incorrect use

If the machine is used incorrectly due to reasonably foreseeable misuse,

the manufacturer's warranty is void and the operating organisation carries sole responsibility.

Reasonable foreseeable incorrect uses are:

• Carrying people.

• Leaving the control stand during operation.

• Placing

• Operating the machine with the floor folded up.

• Spraying with high-pressure cleaners or fire extinguishing equipment.

• Removal

• Failure to observe maintenance intervals.

• Failure to take measurements and perform tests for the early detection of damage.

• Failure to replace wearing parts.

• Failure to perform maintenance and repair work.

• Incorrectly performed maintenance and repair work.

in

operation, use

of

safety features.

of

the machine from outside the control stand.

BAL_1182_2063675_02_EN.doc

15

WIBTGEN

~-

~

1.03

•

Protection

General

Protection

of

the environment

Packaging, cleaning agents and waste or left-over greases, oils and fuel are to be sent for recycling protection

of

the environment applicable

in

accordance with the regulations on the

in

the place

of

the

environment

use.

1.04

Disposal

The protection prevent negative effects on people and the environment and will make it possible to recycle valuable raw materials.

Oils, greases and fuels

Oils, greases and fuels are to be disposed corresponding specifications and the related national regulations.

Materials (metals, plastics)

To be able to dispose type. Clean other substances adhering to the materials.

Dispose

Electrics

The electrical/electronic components are not subject to the WEEE directive 2002/96/EC and the corresponding national laws (in Germany e.g. ElektroG).

Send the electrical/electronic components directly to a specialist recycling organisation.

of

natural resources is a priority task. Correct disposal will

of

materials

I electronics

of

in

accordance with the

of

these materials correctly, they must be sorted by

in

accordance with the related national regulations.

BAL_1182_2063675_02_EN.doc

17

General

Type plate

1.06

3----

Type plate

Fig. 1.1: Type plate

1 Side trim panel 2 Type plate

2

1182_087.jpg

3 1.0. number

All the information is

changed or rendered illegible.

Enter the data on the type plate in table below.

1.

Series I type

2. Machine I.D No.

3. Year

of

Manufacture

4. Output kW I min·

5. Output kW I min·

6.

Admissible

Axle Load

7.

Admissible Total Weight

8.

Operating weight

of

documentary value and

1

Front Rear

9. Max. Operating Weight

Tab.

1.1: Data on

the

type plate

is

not allowed to be

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

19

WIBTGEN

GROUP

'.:..._/

~-

•

General

Technical data

1.08

1.09

Technical data

The technical data

on

the machine are given

in

Personnel -qualifications and obligations

Only authorised personnel are allowed to perform any activities on the machine.

The authorised personnel must:

• Be at least

•

Be

trained

• Have read and understood the safety manual. Be

familiar with and able to apply accident prevention regulations and

• safety instructions

•

Be

appropriately trained and instructed

malfunction.

• Have the physical and mental faculties to be able to perform his/her responsibilities, tasks and activities on the machine.

• Be appropriately trained and instructed for his/her responsibilities, tasks and activities

• Have understood and be able to practically implement the technical documentation related to his/her responsibilities, tasks and activities on the machine.

18 years

in

first aid and be able to provide first aid.

of

on

the machine.

on

the machine.

age.

on

how to react

section 4.

in

case

of

a

in

Prior to placing the machine

• The operating instructions.

• The safety manual.

It is only allowed to employ people to drive machines who also:

• Have been instructed on driving the machine.

• Have demonstrated their skills to the employer.

• Can be expected to reliably tackle the tasks given to them.

They must be appointed by the employer machine.

Follow the instructions below:

• Familiarise yourself with the equipment fitted to the machine.

• Only drive the machine when you have fully familiarised yourself with the controls and method

• Familiarise yourself with your working area.

• Only use the machine for the purpose intended.

• Use suitable lifting gear for fitting heavy extensions or accessories.

operation, read:

of

operation.

I organisation to drive the

BAL_1182_2063675_02_EN.doc

21

General

Personnel -qualifications

Note the instructions below:

• Familiarise yourself with the dimensions of the road paver and the lowloader.

in

case

of

• Wear warning clothing

• Assistance can be by radio (for example

visual contact.

on

loading using the crane) or

by hand signals (for example on reversing the road paver).

of

• The meaning

the signals must be clarified beyond doubt between

driver and assistant.

Service personnel

The service personnel are responsible for ensuring that:

and

obligations

1.09.01

• The safety markers and instructions on the machine are condition.

• The machine is protected against unauthorised use.

• Repairs are discussed with the manufacturer.

• The machine is only operated when it is fully functional and working order.

Personal safety equipment

All parts on the machine described

• Safety shoes

• Safety gloves

• Ear defenders

• Warning clothing

of

the personnel safety equipment must be worn for all activities

in

these instructions:

in

legible

in

correct

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

23

GR

UP

~

·~-·

Immunity to interference

This equipment has been designed and tested for industrial use. Nevertheless, the microprocessor technology places a number requirements on the installation. For this reason your attention is drawn to the following installation features that could result in subsequent malfunctions if not observed:

General

safety

General

instructions

of

• Ensure the polarity

• Do not exceed

• A prerequisite for correct operation is a good electrical connection between road paver and housing chassis for the individual

components.

• Only connect screened cables to earth at one end (equipment end).

• Do not supply any other equipment from the connection terminals for

the supply voltage.

• Do not use spare terminals for other connections or equipment.

Fuses

is

Equipment The supply voltages given exceeded.

Configuration

The equipment has a facility for configuration by the user. On reconfiguration, the user must only re-configure the equipment to suit the situation

Potentially explosive atmospheres

fitted with fuses that provide protection against short circuits.

in

the system.

of

the connections is correct.

or

drop below the specified voltage range.

in

the technical data are not allowed to be

NOTE

The equipment is not intended for use in potentially explosive atmospheres.

of

Rectification

Before you start to rectify a malfunction, ensure all power supplies to the equipment are isolated. Faulty equipment should be checked suitably equipped for test purposes. Any attempt to rectify malfunctions on equipment that is still installed could be hazardous for the operating personnel and the system. Before you remove equipment, ensure the power supply is isolated.

In

case

of

VOGELE supplier.

If the precautionary measures listed above are not observed, the equipment or system may fail. Damage caused by the failure to observe the precautionary measures listed above is excluded from the manufacturer's warranty.

malfunctions

questions

in

or

replace sensors on the

on

operation and installation, please contact your

a facility

BAL_1182_2063675_02_EN.doc

25

1.11.01 Safety distance between working area and road traffic

General

Hazard

2

area

0000_003.jpg

Fig. 1.3: Safety distance between working area and road traffic

1 Road traffic 2 Working area

The safety distance between the working area and road traffic is to be maintained as per national regulations.

In

Germany the following apply:

fOr

• Richtlinien (Directives for securing road works)

• Zusatzliche Technische Vertragsbedingungen und Richtlinien Sicherungsarbeiten an Arbeitsstellen an (Additional technical contract conditions and directives on securing road works) [3]

• Baustellenverordnung (Decree on construction sites) including the related "Rules for health and safety on construction sites" (RAB) [5]

die Sicherung von Arbeitsstellen

an

Stra~en

(ZTV-SA 97)

(RSA)

fOr

BAL_1182_2063675_02_EN.doc

27

I

Pmax=

2kW

General

Labelling

Load earthed socket with maximum 2 kW

l

NOTE

Maintenance instruction

Read operating instructions for information tension on the crawler tracks.

Stipulated drive chain tension

To tension the drive chain can move.

Excessively loose or excessively taut drive chains will result in increased wear

Warning of a crushing hazard

I reduce the tension, adjust the tensioning bracket such that

on

the idler sprocket and drive bearings.

on

tensioning the crawler tracks

on

tensioning/reducing the

in

the auger box

I keep away

by

Joseph

NOTE

Vogele

Lifting points on the machine

It is only allowed to use the eyes marked in this way for loading the machine (for example using a crane).

Never lift the road paver at the screed.

Lashing points

It

is

only allowed to use eyes marked

(for example for transport

AG

BAL_1182_2063675_02_EN.doc

on

the machine

on

a low-loader).

in

this way for lashing the machine

29

W!BT{JEN

GROUP

\.....;__;/

~-

•

2M3S12

" I /

0

General

Labelling

Headlight

Beacon

Prohibited action label: no water

The operator's console and heating switch box must not come into

contact with water when the machine against rain.

is

cleaned and must be protected

1

'-'

0

-·-

Instruction label: wear ear defenders

The operator must always wear ear defenders when operating the machine.

.

Prohibited action label: access forbidden for unauthorised persons

Towing

Lashing points

©

2008

by

Joseph

Vogele

AG

Loading

BAL_1182_2063675_02_EN.doc

31

General

Labelling

1.12.03

6.4

e]

Labels used - USA version

This sub-section provides you with information on the special function of the labelling.

CD

Special hazards and precautions

~l*~

-·

NOTE Welding work

qualified personnel.

Operating instructions and safety manual

if

on

the machine is only allowed

welding is necessary.

to

be performed by

Service addresses

i~--

...

·-

~

===~·-

f B

:--·---

! ...

,._

...

---

;

~"w;,;,~~.':':':.:.,;:!.,.~,!A

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;::

~:::;~:1:;~;;

.-:~!..J~J·•ti$1~,~~~

"~,,.,__

r,.,.c..,d<¢J~1)J...>H

'..,';"'-:...;.-;~

:

.

.......

, ;

;

..

':.-!:-.~~~.~

.

.,,_/'

• Patents

-"--~-'-"'""'''"""""""''~-

fi"'.,.~

..

,t>.l>O'<¥

Special greases

Only grease with a specific specification lubricating system.

Check

Start engine (concise instructions).

list

for

VOGELE after sales service

is

allowed to be used for the

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

33

GROUP

~~-·

"'-./

General

Labelling

r&Wt

•

..

_-"'~!"""'""'

~~~~«~

.,.,.._

""""""""'""¥~

-

••••

Warning

Hazard

Prior to touching, wait until all machine components have come to a complete stop.

Hazard due to rotating parts

of

a crushing hazard (open belts

of

crushing hazard (hand)

due

to

rotating parts (engine end)

or

chains)

NOTE

Tripping hazard - distribution

Lifting points on the machine

It is only allowed to use the eyes marked

machine (for example using a crane).

Never lift the road paver at the screed.

Lashing points on the machine

It is only allowed to use eyes marked in this way for lashing the machine (for example for transport

auger

on

a low-loader).

in

this way for loading the

BAL_1182_2063675_02_EN.doc

35

WIRTGEN

GROUP

~-

\..;J

•·

fhrlz4VDC

201l6i'll.l

General

Labelling

Headlight

;

,,/

n

Beacon

24V~~.

Prohibited action label:

The operator's console and heating switch box must not come into contact with liquid when the machine is cleaned and must be protected against rain.

Instruction label: wear ear defenders

The operator must always wear ear defenders when operating the

machine.

Prohibited action label:

no

liquids

access

forbidden for unauthorised persons

on

Instruction

Loading

BAL_1182_2063675_02_EN.doc

the location of the towing point

on

towing

37

Description/operation

Description

2

2.00

2.00.01

DESCRIPTION/OPERATION

The road paver assemblies are described in section 2.00. Section 2.01 describes how the assemblies and the road paver are

ClJ

Description

Chassis I safety features

operated. Item numbers on general illustrations are marked in the text with round

brackets(). Item numbers on illustrations of specific parts are marked in the text with

square brackets

[].

Fig. 2.1:

(1) Operating instructions and

warnings (2.00.01.01) (2) Trim panels (2.00.01.02) (3) Lighting

(2.00.01.03) (4) Safety devices (2.00.01.05)

Safety features are fitted to the road paver to protect people and property.

~

Ensure the safety features are not damaged and function correctly!

AG

BAL_1182_2063675_02_EN.doc

Safety

features

I warning features

on

the

road

paver

(5) Rail

(6) Hand rail (7) Chassis

(8) Towing point

1182_003.jpg

39

Description/operation

Description

1182_005.jpg

Fig.

2.3:

[4]

Hydraulic tank/sockets

maintenance flap

[5]

Engine/fuel filter maintenance

flap

The bonnet [1] provides protection against heat and noise. It is secured

against falling by a gas strut.

The side trim panel [2] can

NOTE If the driver's seat is pivoted out, the side trim panel can only be locked

in the bottom position.

Trim panels and bonnet are secured with square drive locks when closed. The engine maintenance flap

a rope.

The hydraulic tank/sockets maintenance flap and secured using square drive locks.

NOTE Shut down engine prior to opening trim panels.

Trim

panels

(II)

[6] Operating instructions/ first-

be

locked in two positions.

[3]

is locked using a catch and secured with

aid

box storage compartment

[4]

is locked using a guide

With the SUPER 1800-2 SprayJet the storage compartment for the

[6]

operating instructions/first-aid box box

is

instead mounted

instructions and the first-aid box.

BAL_1182_2063675_02_EN.doc

on

the screed intended to store the operating

is covered by the spray module. A

41

~IBTGEN

ROll

'-.;_/

~-

.•

P

Road paver with roof (option)

Description/operation

Description

···1

ttJ

1182_006.jpg

Fig. 2.5:

[10] Beacon

Either four halogen spotlights or xenon spotlights [7] are available, these are integrated

There are two halogen spotlights [8] on the side for the working area. Two beacons

front and rear right and rear left

Risk of dazzling due to incorrectly adjusted spotlights

Incorrectly adjusted spotlights can cause road accidents.

• Do not twist spotlights

Beacons

in

the front and rear

[1

0]

are available as an option. The beacons are fitted to the

of

the roof. The electrical connection is made on the front

of

the roof.

or

of

the roof.

make similar changes.

BAL_1182_2063675_02_EN.doc

43

21

Balloon light

Fig.

2.7: Balloon light

Description/operation

Description

0774_073.jpg

[12] Balloon light

Up to two balloon lights are available as bright light thanks to halogen lamps. The balloon lights are mounted behind the driver's seats.

an

option providing a smooth and

BAL_1182_2063675_02_EN.doc

45

24

14

Description/operation

Description

1182_047.jpg

Fig. 2.9: Sockets (II}

[22] 24 V beacon socket [23] 24 V spotlight socket

NOTE The 24 V sockets [24] are live when the ignition is switched

[24] 24 V socket [25] Earthed socket (option)

on.

The 24 V sockets for the beacon [22] and spotlights [23] are switched and off via the operator's console.

NOTE The earthed socket [25] has a voltage of 230 V and a frequency

60Hz. At full throttle the earthed socket [25] shuts down automatically to

protect equipment connected.

With the SUPER 1800-2 SprayJet the earthed socket [25] is mounted on the left behind the driver's seat.

Hazard due to electric shock

In

case of overload, cables and electrical components may be live and

cause injury.

In

case

of

• socket, it

connection

is

not allowed to switch on the screed heating.

an

item of electrical equipment to the earthed

• Ensure the diesel speed adjustment is set to the lowest setting (idle speed).

• Wear personal safety equipment.

• Observe safety manual.

of

on

50 -

BAL_1182_2063675_02_EN.doc

47

Description/operation

Description

2.00.01.05

Safety devices

Fig.

2.

14:

Safety devices

on

the road paver

1182_003.jpg

[32] Hopper wall locking pins [33] Seat locking pin [34] Roof

During transport the hopper walls [32], the screed, the roof [34], the seats [33] and awning [35] (retracted) must

[35] Awning locking pins

[36] Roof locking pins [37] Screed locking pins

be

locked.

AG

BAL_1182_2063675_02_EN.doc

51

WIBJGEN

GROUP

~-

"-..J

2.00.02.01 Operator's console

•

Operator's console with mountings

Description/operation

Description

Fig. 2.16:

Locking lever for sliding [5] Cable duct

[1]

[2]

Locking lever for turning left [6] [3] Foot lever for tilt adjustment [4] Locking lever for turning right

If the locking lever [1] is pressed, the operator's console can be slid along

the guide rail [6]. To turn, pull locking lever [2] or [4].

NOTE The cable duct [5] must not be trapped.

The mounting must engage after it has been adjusted.

Ignition key [7]

The road paver's power supply is switched on and off.

• Position 0 electrically isolates the road paver

• Position 1 activates the control voltage for engine, control electrics and lighting.

Operator's console with mountings

Guide rail

[7]

Ignition key

1182_011.jpg

by

Joseph Vogele AG

BAL_1182_2063675_02_EN.doc

53

WIRTGEN

GROUP

~-

~

10

•

Description/operation

Description

Operator's console for material conveying and propulsion (left)

MMI_001.jpg

Fig. 2.18: Operator's console for material conveying and propulsion

(left)

[1]

Emergency stop [8]

[2] Reversing conveyors

[3] Distribution auger height

adjustment

[4]

Conveyors I distribution [11] Right distribution auger augers

Reversing crawler tracks

[5]

Control knob for paving (13] Automatic filling

[6]

speed

[7] Operating mode selector

switch

Emergency stop [1]

The diesel engine, all units and the screed are shutdown when the emergency stop button is actuated. To reset the emergency stop state, turn emergency stop button clockwise.

All functions on the road paver must be switched start the road paver.

I tamper

Main drive switch

[9] Right conveyor

Left conveyor

[10]

[12] Left distribution auger

off

so that you can re-

by

Joseph Vogele AG

Reversing conveyors

Both conveyors reverse at moderate speed.

BAL_1182_2063675_02_EN.doc

[2]

55

WIBTGEN

GROUP

~-

"-.J

I

Description/operation

Description

• Neutral

- Diesel engine warm up.

- Screed warm up.

- All drives are disabled except diesel engine and screed heating.

- The road paver cannot be

• Manoeuvring

- Manoeuvring on the construction site.

- All automatic functions are inactive.

• Positioning

- Sensitive driving, e.g. for moving the road paver to a point.

- Road paver reacts exactly to movements joystick [28].

• Paving

- Lays the mix on the pre-base.

- All functions and screed float are active.

moved.

of

the steering

new

starting

17

F

~

Main drive switch [8)

The road paver direction

• Switch position

• Switch position (R) - drive backward

• Switch position

•

J

R

NOTE

In switch also regulates the road speed.

• Switch position (F) - drive forward

• Switch position {R) - drive backward

• Switch position (P) - stop

of

travel

is selected:

(F)-

drive forward

(P)-

stop (park position)

the manoeuvring and positioning operating modes, the main drive

- To

move forward, release lock (A) and move main drive switch

forward.

- Paving operating mode: road paver moves forward without steps the control knob for road speed [6] is turned from the zero position.

-

Manoeuvring

forward without steps

- To

move backward, release lock (A) and move main drive switch

backward.

- Manoeuvring and positioning operating mode: road paver moves

backward without steps backward.

- The parking brake is activated. Traction drive pumps on the

hydrostatic compact drive are switched off.

- The automated grade and slope control is switched off.

- Conveyor and compaction systems switched to automatic are

switched off.

and

positioning

operating

if

the main drive switch is pressed forward.

if

the main drive switch is pressed

mode:

road

paver

moves

if

by

Joseph Vogele

AG

BAL_1182_2063675_02_EN.doc

57

~

WIBIGEN

OfiOUP

~

14

Description/operation

Description

Operator's console for screed functions (middle)

22

NOTE

Fig.

2.19: Operator's console for screed functions (middle)

tow

Left

[14]

[15] Right tow point ram [19] [16] Screed assist [20]

[17] Raising/lowering,

mechanically locking screed

point ram [18] Right extending unit

Left extending unit Screed heating

Left tow point ram [14]

The switch has the following functions:

• Top button: left tow point ram for the screed is raised.

• Bottom button: left

The switch for the right tow point ram [15] functions similarly.

tow

point ram for the screed is lowered.

Screed assist [16]

Screed assist is switched

or

off.

MMI_003.jpg

by

Joseph Vogele

NOTE The screed assist is only active with screed float.

AG

BAL_1182_2063675_02_EN.doc

59

21

Description/operation

Description

Operator's console for material hopper and steering (right)

31

,I,

Q

Fig. 2.20: Operator's console

[21] Beacon

Screen wiper [28] Steering joystick

[22]

Steering trimming [29] Horn

[23] [24] Lighting [30] Adjust diesel speed [25] Move left hopper wall

Move right hopper wall

[26]

Beacon [21] (option)

The 24 V socket for the beacons

for

material hopper

[27] Hopper walls/entry flap

[31] Start/shut down engine

is

switched

on

and

or off.

steering (right)

26

MMI_002.jpg

Screen wiper [22] (option)

Screen wiper is switched or off.

Steering trimming [23]

The switch has the following functions:

to

• Left button: road paver steers continuously

• Middle button: road paver moves straight ahead.

• Right button: road paver steers continuously

BAL_1182_2063675_02_EN.doc

the left.

to

the right.

61

WIRTGEN

GROUP

~-

"'-J

.•

Description/operation

Description

Adjust diesel speed [30]

• MAX - maximum paving performance

- Usage: paving and heating

• ECO - reduced fuel consumption and wear (reduced paving performance)

- Usage: paving and heating

MIN-

•

You select the diesel speeds using the buttons. Once a diesel speed has been selected, the related light emitting diode illuminates. If automatic diesel speed adjustment is active, the diode flashes.

Start/shut down engine [31]

• Starting engine: never keep button pressed for more than 1 0

• Shutting down engine: keep button pressed for more than one

idle

- Usage: heating

seconds.

second.

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

63

Description/operation

Description

Navigation block [34]

Using the navigation block you can enter values and navigate on the display pages.

The navigation block has the following functions:

• ESC button:

- Change to higher level display pages

- Discard values

• Return button:

- Save values

• Arrow buttons:

- Page within the display pages

- Increase or reduce values

Malfunction indicator [35]

Flashes if there is a malfunction on the road paver.

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

65

m/min

D

.a

Description/operation

Description

53

CJ

56

55---L??)

54

-

&I

AI

Fig.

2.23: Start page

(53]

Steering sensor error indication

..

• n

l.u

em

Fig.

2.24: Start page

(/)

with active automatic steering system

m/min

D

.a

..

I. D

em

(II)

MMI_DIS_045.jpg

57

MMI_DIS_002.jpg

©

2008

by

Joseph

Vogele

Sub-menu

[54]

Area

for service

[55] Screed heating temperature

regulation

The sub-menu items [54]-[57] open the related sub-menu.

AG

BAL_1182_2063675_02_EN.doc

[56]

Automatic

adjustment

[57] Brightness/contrast

diesel

speed

67

Description/operation

Description

Spray module sub-menu (only

SUPER

Fig. 2.26: Spray module sub-menu

[66] Switch on

spray operation

[67]

Switch on

construction site"

or

off automatic

or

off "start

of

1800-2 SprayJet)

[68] Switch on

construction site"

or

66

67

68

MMI_DIS_058.jpg

off

"end

of

Using the "start function the spray bars can be switched on at specific points. In this way, spraying is started

of

construction site" [67] and "end

at

exactly the required point.

of

construction site" [68]

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

69

WIRTGEN

GROll!'

~-

~

•

Conveyors sub-menu

Description/operation

Description

.....

~-------72

71

Fig.

2.28: Conveyors sub-menu

[71] Indication

percent

flow regulation)

Symbols/indications on

the right

of

rate setpoint (in

of

the max. material

on

is

similar.

the left relate to the left conveyor. The behaviour

MMI_DIS_007.jpg

[72] Entry of rate

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

71

87----r->

Description/operation

Description

Tamper sub-menu

86

13Lf8

&I

Fig.

2.30: Tamper sub-menu

[81]

Switch

operating mode

[82] "Manual" operating mode

ON/OFF indication

[83]

Switch

operating mode

[84] "Automatic" operating mode

ON/OFF indication

on

or off "Manual"

on

or off "Automatic"

1/min

MMI_DIS_006.jpg

[85]

Tamper speed entry

[86] Actual tamper speed

indication (option)

[87]

Tamper speed setpoint indication

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

73

Pressure bar sub-menu

OJ

I

---r---

Description/operation

Description

~----95

96

98

AI

Fig.

2.32: Pressure bar sub-menu

[95] Switch

operating mode

[96] "Manual" operating mode

ON/OFF indication

on

or off "Manual"

MMI_DIS_010.jpg

[97] Switch

operating mode

[98] "Automatic" operating mode

ON/OFF indication

on

or off "Automatic"

by

Joseph Vogele

AG

BAL_1182_2063675_02_EN.doc

75

~-

•

--tl!l

Description/operation

Description

Sub-menu with information on the road paver

'

108 !

107

106-----re

r

105

------r

!

6\

2Q

""J?..'-

~

AI

bar

2

T

Fig.

2.34: Sub-menu

[104] Engine coolant temperature [108] Fuel contents [105] Engine oil pressure [109] [106] Engine speed [107] Operating hours counter

The information

on

&I

I

T T

with

information

the road paver is read

oc

12

~!

0.+

"'

"

on

the

road paver

Paving distance counter

[11

0]

Reset distance counter to

zero

in

rows.

MMI_DIS_003.jpg

The paving distance counter [109] is an approximate figure. Depending on the slip between the tracks or wheels and the surface, the paving distance

[1

counter

09] may vary significantly from the actual distance covered.

by

Joseph Vogele AG

BAL_1182_2063675_02_EN.doc

77

WIRIGEN

GRO\Jf'

'-..;/

~-

•

Automatic diesel speed adjustment sub-menu

[]

0

Description/operation

Description

------118

119

MMI_DIS_011.jpg

Fig.

2.36: Automatic diesel speed adjustment sub-menu

[118]

Switch on or off automatic diesel speed adjustment

The automatic diesel speed adjustment is coupled to the main drive switch [8].

If the automatic diesel speed adjustment is switched on, the road paver runs at the diesel speed set (MIN, ECO, MAX} after the main drive switch [8] is deflected.

[119]

Automatic diesel speed

adjustment ON/OFF indication

by

Joseph Vogele AG

BAL_1182_2063675_02_EN.doc

79

W!BTGEN

GROUP

"-.;/

~-

2.00.02.02 Driver's seat with rails

125

•

Description/operation

Description

124

1182_012.jpg

Fig.

2.38: Driver's seat

[124] Locking pin

[125] Adjust body weight

[126] Removable head rest

The controls are dependent If the locking pin [124] is pulled, the driver's seat mount is unlocked. The

driver's seat (2) can

Side trim panels may be damaged

There is a danger that the driver's seat mount may come into contact

with the side trim panel and damage the panel.

The side trim panels must

• Be closed and locked or

• Folded to the bottom position and secured.

be

on

pivoted outward.

[127] Folding armrest [128] Adjust seat position [129] Adjust seat height

the seat version.

©

2008

by

Joseph

NOTE The locking pin [124] must re-engage

of the driver's seat.

As

an

Vogele

option the seat

The seat heating is switched

AG

BAL_1182_2063675_02_EN.doc

is

available with heating.

in

the catch after the adjustment

on

or off using a switch on the driver's seat.

81

-

Description/operation

Description

Mounting [133]

Is fitted to the bracket on the screed's end plate.

Warning light [134]

The left warning light flashes as soon as the screed's left extending unit

is extended or retracted. The same applies as appropriate to the right warning light.

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

83

~

WIRTOEN

GROUP

\,J

Description/operation

Right tow point ram [140]

The switch has the following functions:

• Niveltronic® Plus inactive

- Top button: right tow point ram for the screed is raised.

- Bottom button: right tow point ram for the screed is lowered.

• Niveltronic® Plus active

- Top button: the setpoint for the right tow point sensor is increased.

- Bottom button: the setpoint for the right tow point sensor is reduced.

NOTE The switch for the left tow point ram [141] functions similarly.

Screed extending unit [142]

The switch has the following functions:

• Right button: the screed extending unit is moved to the right.

• Left button: the screed extending unit

is

moved to the left.

Description

Screed float [143]

Screed float is switched or off. In

the paving operating mode the screed float is always active

main drive switch [8] is

in

position

F.

Conveyors [144]

The switch has the following functions:

on

• Top button: automatic mode is switched

or off.

• Bottom button: conveyors run at maximum speed.

if

the

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

85

Description/operation

Description

Display [148]

The road paver, screed and Niveltronic® Plus (option) functions are

on

displayed

Display switching [151]

Change between Niveltronic start page and a display page.

the display.

NOTE

If the Niveltronic® Plus (option) is activated, the display switching [151] changes between the brightness/contrast display page and a display page.

Display pages

The display has the following pages:

• Niveltronic

• Machine

©

2008

by Joseph V6gele AG

BAL_1182_2063675_02_EN.doc

87

GROUP

"'-./

~-'

Symbols for the tow point ram sensors

Tab.

2.1:

Description/operation

Description

Tilt sensor

Long range ultrasonic sensor on ground

Long range ultrasonic sensor on rope

Symbols for the tow point ram sensors

Niveltronic parameters

II;~

Fig. 2.43: Niveltronic parameters

[167] Open Niveltronic sensor

[168] Return to Niveltronic start

38.

Scm

calibration

page

38.

Scm

168

MMI_DIS_022.jpg

[169] Open Niveltronic sensitivity

[170] Open brightness/contrast

adjustment

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

89

W!RIGEN

GROUP

~-

~

.•

Description/operation

Description

Niveltronic sensitivity

182

183

5

Fig.

2.45: Niveltronic sensitivity

Niveltronic® Plus left

[180) Increase sensitivity [181] Reduce sensitivity [182] Sensitivity indication

If the value for the sensitivity indications [182], [183) is low, the response

time of the units becomes slower.

Brightness/contrast adjustment {display)

5

MMI_DIS_024.jpg

Niveltronic® Plus right

[183] Sensitivity indication [184) Increase sensitivity [185) Reduce sensitivity

General

[186) Return to Niveltronic start

page

190

38.5cm~5'1

~--~~----~------~----~~~~

Fig.

2.46: Brightness/contrast adjustment (display)

[187)

Increase brightness

[188]

Reduce brightness

[189)

Brightness sensor actual

value [190) Brightness value indication [191] Contrast value indication

191

,......-+----

[192) Temperature sensor actual

value

[193]

Increase contrast

[194]

Reduce contrast

[195]

Return to Niveltronic start page

193

MMI_DIS_023.jpg

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

91

WIRIGEN

GROUP

~-

~

•

Description/operation

Description

Vibration page (option)

cm~-11

1/min---

207

AN

~--------------

Fig. 2.49: Vibration page

[207] Vibration speed actual value [208] Vibration speed setpoint

Pressure bar page (option)

cmJ

208

MMI_DIS_029.jpg

Fig. 2.50: Pressure bar page

Screed assist page (option)

1

t

......

Fig. 2.51:

[209] Pressure distribution setpoint

Screed

__

~-

assist

page

MMI_DIS_030.jpg

----209

MMI_DIS_032.jpg

by

Joseph Vogele

AG

BAL_1182_2063675_02_EN.doc

93

Conveyors page

Description/operation

Description

215

214

cmJ

••

~----------

%-

T

Fig.

2.54: Conveyors page

[213] Rate setpoint

Distribution augers page

em

~.

%-

cm~il

T +

-----------------216

T§¢

cm~il

213

MMI_DIS_028.jpg

Fig. 2.55: Distribution augers page

[214] Switch

sensor

[215] Material sensor ON/OFF

indicator

on

or off material

MMI_DIS_027.jpg

[216] Rate setpoint

AG

BAL_1182_2063675_02_EN.doc

95

Description/operation

Description

2.00.02.04

222

221

220

Roof {Option)

Fig.

2.

58:

Roof

1182_

223

224

013.jpg

[220] Hydraulic pump [221] Awning locking pins

[223] Plastic roof [224] Exhaust pipe

[222] Awning

The awnings [222] can

For transport the roof (4) can

exhaust pipe [224] is folded with the roof

be

extended and retracted.

be

folded using a hydraulic pump [220]. The

(4).

A windscreen and a tarpaulin are available as options.

be

During transport the awnings [222] must

locked

in

the retracted state.

BAL_1182_2063675_

02_EN.doc

97

WIRTGEN

GROVP

\.._;_/

~-

I,

Description/operation

Description

2.00.04

Power unit/engine

Fig.

2.

60:

Power

6

5

7

1182_015.jpg

unit/engine

(1) Engine compartment

(2.00.04.01)

(2) Fuel supply (2.00.04.02), not

shown

(3) Exhaust system (2.00.04.03)

(4)

Air

intake (2.00.04.04)

(5) Cooling system (2.00.04.05)

(6) Diesel speed adjustment

(7) Refuelling system (option)

(2.00.04.06)

BAL_1182_2063675_02_EN.doc

99

WIBIDEN

GROUP

'-,;J

~-

•

Description/operation

Description

SUPER 1800-2

2

Fig.

2.63: Engine compartment(/) (SUPER 1800-2)

Fig.

2.

64: Engine compartment

(II)

(SUPER 1800-2)

1182_016.jpg

3

4

1182_041.jpg

[1] Diesel engine

[2] Engine oil filler

The diesel engine [1] has low emissions and common rail injection. The diesel engine [1] has a turbocharger with intercooler.

BAL_1182_2063675_02_EN.doc

[3] Height indicator bar [4] Engine oil filter

101

WIR~Eti

GAO

~-

'-..../

•

P

2.00.04.02

6

Fuel

Description/operation

Description

supply

8

9

Fig.

2.

66:

Fuel supply

[6] Filler [7] Cap

Fig.

2.67: Fuel supply filter (SUPER

1600-2)

1182_008.jpg

1182_060.jpg

[8] Fuel pre-filter with water trap

When filling the tank with fuel, ensure no dirt enters the tank. Never

run

the fuel tank empty.

The amount of fuel operator's console.

BAL_1182_2063675_02_EN.doc

in

the fuel tank is indicated

[9]

Fuel filter

on

the display

on

the

103

GROUP

~N-1

\_J

Description/operation

Description

2.00.04.04

14

15

16

Air intake

Fig.

2.69: Air intake

18

17

1182_018.jpg

[14] Hose, intake side [15] Air filter [16] Dust discharge valve

There is an indication on the maintenance indicator [18] if the air filter is clogged.

With the SUPER 1800-2 SprayJet the compressor on the engine is

connected to the clean air hose [17] on the air filter [15].

[17] Clean air hose [18] Maintenance indicator

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

105

Description/operation

Description

19

SUPER

Fig.

2.

1800-2

72:

Combined cooler (SUPER 1800-2)

[19] Cover [20] Hydraulic oil cooler

20

21

22

1182_019.jpg

[21] Radiator

[22] Intercooler

23

Fig.

2.

73:

[23]

Expansion vessel

Expansion vessel (SUPER 1800-2)

[24]

Sight glass

24

1182_020.jpg

©

2008

by

Joseph

Vi:igele

AG

BAL_1182_2063675_02_EN.doc

107

WIBTGEN

GROUP

'-....;/

~-

•

Description/operation

Description

2.00.04.06

26

Refuelling system (option)

Fig.

2.

75:

27

1182_024.jpg

Refuelling system

[26] Electrical diesel pump

With the aid diesel from a drum.

of

the refuelling system, the road paver can be refuelled with

[27] Fuel tank

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

109

~-

2.00.05.01 Hydraulic tank

•

Description/operation

Description

2

3

2.00.05.02

Fig.

2.

77:

[1] Filler [3] Runback suction filter [2]

Overflow oil filter

The level the hydraulic tank and should be between the min and max marks.

The hydraulic system contains two filters, an overflow oil filter and a

runback suction filter; these filters are mounted

The level gauge is only accessible after opening the right side trim panel.

Pump distribution gearbox

The pump distribution gearbox (2) drives the pumps for the entire hydraulic system and is bolted to the diesel engine.

in

1182_007.jpg

Hydraulic tank

the hydraulic tank (1) must be visible on the level gauge on

in

the hydraulic tank.

2008 by Joseph V6gele AG

©

BAL_1182_2063675_02_EN.doc

111

15

Description/operation

Description

Pumps (SUPER 1800-2 SprayJet)

Fig.

[15]

2.

79:

Emulsion

1182SJ_005.jpg

Hydraulic pumps SUPER 1800-2 Spray Jet

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

113

Description/operation

Description

2.00.05.04

20

21

Control blocks

Fig.

2.81: Control blocks

1182_026.jpg

(I)

22

[20] Ram functions I

Fig.

2.

82:

Control blocks

(II)

[21] Ram functions

II

23

1182_027.jpg

Joseph

Vogele

[22] High pressure (option)

AG BAL_1182_2063675_02_EN.doc

[23] Retract

or

extend screed

115

WIRTGEN

~-

e:

•

Description/operation

Description

2.00.05.05

26------

Partial flow filter for bio-oil (option)

Fig.

2.84: Partial flow filter for bio-oil

27

1182_029.jpg

[26]

Pressure gauge

[27] Cover

The partial flow filter for bio-oil is beside the tamper and vibration control

blocks in the hydraulic tank/sockets maintenance flap. If the road paver is operated with bio-oil, the partial flow filter must be

fitted.

Risk of damage to the machine

The machine

• Before bio-oil is added, all parts that have been in contact with mineral oil must be thoroughly cleaned and flushed.

may

be damaged if bio-oil is mixed with mineral oil.

[28] Container

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

117

Description/operation

Description

4

5

1182_030.jpg

Fig.

2.

86:

Electrical system

(4) Switch box 24 V-power

supply (2.00.06.02)

(II)

(5) Heating switch box

(2.00.06.03)

A differentiation is made between two supply networks in the electrical

system:

• The

24 V DC network supplies the engine, lighting and control

electronics with the necessary electrical power.

400 V supply network supplies the screed heating with the

necessary power.

by

Joseph Vogele AG

BAL_1182_2063675_02_EN.doc

119

WIR].'aEN

GROUP

~-

~

•

Description/operation

Description

2.00.06.03

Heating switch box

Fig.

2.91: Exterior

of

heating switch box

5

1182_009.jpg

NOTE

Warning light (red)

[5] Circuit breaker monitoring

[6] Insulation monitoring unit

The heating switch box (4) is underneath the right driver's seat. The

heating switch box (4) can be accessed if the driver's seat is pivoted outwards.

The sockets on the heating switch box are described in

section 2.00.01.04.

Do not spray heating switch box with water.

Hazard due to water

Water

may

enter the heating switch box and cause damage and injury.

• Do not spray heating switch box with water.

• Wear personal safety equipment.

• Observe safety manual.

in

the heating switch box

Warning light (green)

[7] Heating power boost

[8] Right screed heating

[9] Left screed heating

BAL_1182_2063675_02_EN.doc

123

12

Description/operation

Description

Heating switch box (SUPER 1800-2 SprayJet)

13

1182SJ_006.jpg

Fig.

2.

93: Side emulsion tank

[12] Emulsion tank [13] Heating switch box

If

The heating switch box [13] is underneath the emulsion tank [12].

the emulsion tank [12] is tipped upwards (in the direction of the driver's seat), the heating switch box [13] is accessible.

BAL_1182_2063675_02_EN.doc

125

z.oo.os.04

Generator

Fig.

[151

2.95:

V-bel1s

Generator

example

[161

Belt

pulle~

2.00.07

Not used

The

400 V power

generator

The

gene<ator

provides

earthed

(5)

is

driven

(5)

the

three-phase

socket

suppl~

(option).

directlY

is a

brush-less

is

provided

from

power

by

the

generator

the

pump

synchronous

necessary

for

distribution

generator.

the

(5).

screed

The gearb<

The' hea'

-,.,nh

Vogele

AG

BAL_1182-

2063675-02-

EN.doc

Description/operation

Description

2.00.08.01

Feed pumps for the hydrostatic compact drive

Fig.

2.97: Feed pumps

2

1182_067.jpg

[1]

Oilfilter

[2]

Pump distribution gearbox

The oil filter [1] for the traction drive pumps for the hydrostatic compact

on

drive are

the pump distribution gearbox [2].

BAL_1182_2063675_02_EN.doc

129

Description/operation

Description

2.00.10.03

9

Distribution augers

SUPER 1600-2

10

1182_037.jpg

10

Fig.

2.

105: Distribution auger (SUPER 1600-2)

[9] Auger box

SUPER 1800-2

[1

0]

Gearbox

9

©

2008

by

Joseph

Vogele AG

Fig.

2.

106: Distribution auger (SUPER 1800-2)

[9] Auger box

BAL_1182_2063675_02_EN.doc

[1

0]

1182_038.jpg

Gearbox

137

W!RTGEN

GROUP

"-._/

~-

•

Description/operation

Description

2.00.11.02

Spirit level

Fig.

2.

118: Spirit level

1182_051jpg

2.00.12

Not

used

[4]

Spirit level

The spirit level [4] indicates the tilt on the screed

horizontal. The position of the screed can

the spirit level

[4]

and adjusted on the outer control stands.

be

read using the level glass on

in

relation to the

BAL_1182_2063675_02_EN.doc 147

W!RTG!;N

GROUP

~-

"-../

•.

As an option a cleaning system is available. The cleaning system is used for applying the release agent with the aid of a spray nozzle [5].

[1]

The pump spray nozzle

NOTE Do not use the following cleaning agents:

• petrol

• highly flammable substances

• aggressive substances Observe the applicable safety instructions for the related cleaning agent.

Hazard due to incorrect handling of release agents

Release agents and their vapours are inflammable and harmful for the health.

• Do not smoke during filling.

• Do not bring any naked flames near the tank during filling.

• Wear personal safety equipment (e.g. safety gloves and face mask).

pumps the release agent from the release agent tank to the

[5]

via a hose.

Description/operation

Description

Release agent tank

6

7

1182_041.jpg

Fig.

2.121: Release agent tank

[6]

Filler

[7]

Release agent tank

When filling the release agent tank, ensure that no soiling enters the tank.

BAL_1182_2063675_02_EN.doc

149

WIRTGEN

GROUP

~-

~

•.

Description/operation

Description

2.00.14

2

Screed attachment

Fig.

2.

123: Screed attachment

3

1182_003.jpg

(1) Tow point arm

(2) Tow point ram (2.00.14.01)

(3) Screed lifting ram

(4) Screed assist (option)

(2.00.14.02)

Adapter plates are available as an option; these plates allow crown adjustment from

The fitting and removal of the adapter plates is described

-2.5% to +5%.

(5) Screed mechanical lock

(2.00.14.03)

(6) Electrical and hydraulic road

I screed connection

paver

(2.00.14.04), not shown

(7) Tow point arm adjustment

(2.00.14.05)

in

section 5.04.

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

151

Description/operation

Description

2.00.14.01

2

Tow point ram

Fig.

2.125: Tow point ram

3

4

1182_043.jpg

[2] Scale

[4] Height indicator bar

[3] Travel measurement sensor

connection

The screed position setpoint is adjusted using the tow point rams (2). The

of

position

the tow point rams (2) is changed using the screed function

the operator's console and the outer control stands. The scale [2] on the tow point ram (2) provides a rough indication.

NOTE Due to the integrated travel measurement, the height adjustment

tow point rams can be read on the displays (operator's console and outer control stand).

of

on

the

©

2008

by

Joseph

Vtigele

AG

BAL_1182_2063675_02_EN.doc

153

Description/operation

Description

2.00.14.03

Screed mechanical locking

Fig.

2.

127: Screed mechanical locking

7

1182_003.jpg

[7] Locking pins

The screed rail guide plates on the rear wall must be

in

the outer position.

When transporting or manoeuvring on the construction site, both tow point arms (1)

on

the screed must be in contact with the locking pins [7].

NOTE The screed has maximum ground clearance when the screed lifting

rams (3) are raised completely such that the attachment point on the

in

tow point arms is

the lowest position.

The screed locking is mechanical. Hydraulic screed locking is available as an option.

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

155

W!RTGEN

GROUP

~-

~

•

Description/operation

Description

2.00.14.05 Tow point

10

11

arm

adjustment

Fig.

2.129:

[1

0]

Screed position

[11] High screed position

Tow

point arm adjustment

12

13

1182_046.jpg

(12]

Screed position offset to rear

[13] High screed position, offset to

rear

2.00.15 Not used

The screed position [10], [12] is for a paving thickness up to 20 With the screed positions offset to the rear [12], [13] the distance between

80

the screed and the auger is increased by The adjustment of the tow point arms is described The height

and outer control stand) and on the scales. The values give the parallel distance between screed and pre-base.

of

the screed is indicated on the displays (operator's console

mm.

in

section

em.

5.

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

157

Description/operation

Description

2

1182SJ_026.jpg

Fig.

2.

131: Lifting arm

[1]

Lifting arm

[2]

Guides

The SprayJet module can be tipped inwards using the lifting arm [1]. The

[1]

lifting arm

is stowed under the emulsion tank ( 1

).

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

159

Description/operation

Description

2.00.16.02

Heating

Fig.

2.

133:

Heating

2

1182SJ_009.jpg

(/)

4

1182SJ_024.jpg

Fig.

2.

134: Heating

[1]

Heating

[2]

Temperature gauge

(II)

[3]

Fumes opening

[4]

Additional gas heating

The emulsion tank is electrically heated and insulated. The heating

3

[1]

comprises two heating rods inside the emulsion tank. The heating shuts

in

down when the level

the emulsion tank (1)

is

too low.

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

161

Description/operation

Description

1182SJ_021.jpg

Fig.

2.

139:

Emulsion pump

[4] Filter

[5] Pressure gauge for spray

pressure

The shut-off valves [1], [2] on the emulsion pump [3] have the following functions depending on their position:

Spray emulsion

Fill emulsion tank

Transfer pump emulsion into the emulsion tank

(1/)

[6] Meter pump lever (hand-held

spray lance)

[7] Meter pump lever (transfer

pumping)

[~

J&]

I~

I Clean emulsion pipes

AG

BAL_1182_2063675_02_EN.doc

wilh

compressed air

or

release agenl

165

Description/operation

Description

The spray bars (5) apply the emulsion to the road surface. There are two,

five or six spray nozzles [5] on the spray bars (5). The outermost spray

nozzles

The folding spray bars

sliding pipe [2]. If the paving width is changed, the folding spray bars [3] are also moved.

[5] can be shut down separately.

[3] are connected to the extending screed using a

2.00.16.06

Fittings

Fig.

2.

1182SJ_019.jpg

142: Fittings

[1] Connection and shut-off

valve, emulsion pipes, spray bar

©

2008

by

Joseph

V6gele

AG

BAL_1182_2063675_02_EN.doc

167

Description/operation

Spray module function selector switch [5]

The following SprayJet module functions can be selected:

•

1-0ff

• 2 - Fill I empty tank

• 3 - Circulation mode

• 4

-Automatic

The SprayJet module is coupled to the main drive switch.

• 5 - Hand-held spray lance

• 6 - Maintenance

Switch on/off spray module (6] I [7]

spray mode

Description

BAL_1182_2063675_02_EN.doc

169

Settings sub-menu

Description/operation

Description

27

26 25

24

23

Fig.

2.

145: Settings sub-menu

[16] Software version indication [17] Test sub-menu [18]

Processor temperature indication

[19]

Processor PCB temperature indication

[20]

Reset of processor

and processor PCB temperature, only possible with servicing authorisation

[21] Page number

1182SJ_D_001.jpg

[22]

Back to the previous page [23] Service sub-menu [24]

Language selection sub-

menu [25]

Heating sub-menu

[26]

Manual (emergency

operation) sub-menu

[27] Sub-menu symbol

16 17

18

19

20

21

22

AG

BAL_1182_2063675_02_EN.doc

171

WIRT<tEN

ORO P

~-

"-.../

.•

Description/operation

Description

Heating sub-menu

34

33

32

Fig.

2.

147: Heating sub-menu

[29] Indication of emulsion pumps

temperature

[30] Adjust emulsion pump

temperature setpoint

[31] Switch

temperature monitoring

on

or off automatic

29

30

31

1182SJ_D_003.jpg

[32] Switch

tank temperature monitoring

[33] Set emulsion tank

temperature

[34] Indication of emulsion tank

temperature

on

or off emulsion

BAL_1182_2063675_02_EN.doc

173

Test sub-menu

Description/operation

Description

52

51

50

49

1182SJ_D_005.jpg

Fig.

2.149: Test sub-menu

[49] Nozzle check [50] Nozzle pre-selection sub-

[51] Nozzle cycle sub-menu

[52] Nozzle test

menu

The Nozzle check [49] checks the correct function of each single spray nozzle in conjunction with control valve and bellows, see Maintenance section.

The Nozzle test [52] checks whether the spray nozzle works.

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

175

Parameters sub-menu

Description/operation

Description

Spray

pressure

Spraying

Fig.

(56] Adjust spray pressure

[57] Adjust sprayed amount for

Parameter

set

point

quantity

spot

quantity

2.

152: Parameters sub-menu

one nozzle

of

one

length

offset

56

57

58

59

1182SJ_D_011.jpg

(58]

Ajdust sprayed area

direction of travel [59] Adjust sprayed amount offset

in

the

Language selection sub-menu

Fig.

2.

153: Language selection sub-menu

1182SJ_D_009.jpg

177

60

Description/operation

Description

Operator's console cover

Fig.

The operator's console is protected against wanton damage and the machine protected against unauthorised use using a cover [60].

2.00.16.08 Cleaning system

3

2

2.

155: Emulsion tank and operator's console

[60] Operator's console cover

1182SJ _ 027

.jpg

1

by

Joseph Vogele AG

Fig.

2.

156: Cleaning system

[1] Fitting for blowing out with air

[2]

Flushing connection

BAL_1182_2063675_02_EN.doc

1182SJ_010.jpg

[3] Air pressure gauge

179

2.00.16.10 Labelling

Description/operation

Description

Filling

Emulsion pipes

Emulsion

The emulsion tank is no longer heated when the level is low.

Cleaning emulsion pipes

with

emulsion

to

tank

level gauge

the spray nozzles

with

compressed

air

'it\if\i

r

...

~

~l[!j}

~

ID!l

~

0

Bypass function

Transfer pump

Metering pump

Prohibited action label: do

Emulsion tank pump lever settings

I hand-held

spray

not

enter emulsion

lance

tank

BAL_1182_2063675_02_EN.doc

181

Wifi\%EN

GAO

\.',,,,,J

~-

~

I

I'

2.00.18 Central lubricating system

1

2

Description/operation

Description

4

3

2.00.19 Screed

1182_023.jpg

Fig.

2.

159: Centra/lubricating system

(1) Cap

(2) Grease nipple, maintenance

The central lubricating system is in operation after the conveyors and augers are switched on.

The central lubricating system supplies all key lubricating points on the conveyors and distribution augers with grease.

Prior to every time the machine is used it must be checked whether there

is sufficient grease in the reservoir (2), if necessary top up central lubricating system with grease.

As an option a grease gun is available for filling the reservoir (2).

See screed operating instructions.

(3) Grease nipple, filling ( 4) Reservoir

BAL_1182_2063675_02_EN.doc

183

Description/operation

Operation

2.01.01

Placing road paver in operation

Check the following points prior to placing the road paver in operation:

• Function

• Fuel tank and fuel pipes for leaks.

• Hydraulic tank and fuel pipes for leaks.

• Condition

• Tension

• Correct seating

• Engine oil level.

• Hydraulic oil level.

• Oil level in the pump distribution gearbox.

• Amount

• Lubrication

• Amount

with spray module:

• Function

• Emulsion tank and pipes for leaks.

• Emulsion level.

• The rear-view mirror must be fitted, correctly adjusted and free of soiling.

• Small limiting plates must be mounted.

of

the emergency stop button.

of

the safety features.

of

the brakes.

of

the steering.

of

engine and machine.

of

the crawler tracks.

of

the bolted joints.

of

grease

of

diesel

of

in

of

the conveyor mounts.

in

the fuel tank.

the spray nozzles.

the auger box.

Prior to the checks must be made particularly carefully.

Top up oils and grease lubricant comparison table are given in section

Hazard due to incorrect operation!

There is a risk of injury

Use an assistant you to see.

an

extended period

• The road paver is only allowed to be operated from the control stand from a seated position.

• During work on the edge and embankments the road paver must that there is no risk of falling.

if

there are areas around the machine which are hard for

BAL_1182_2063675_02_EN.doc

of

operation or after a long period without use,

as

necessary. Maintenance schedule and

4.

if

the machine is operated incorrectly.

of

large holes, trenches, piles of material

be

kept sufficiently far away

185

WIRTGEN

GROUP

~-

"-.-/

•

Description/operation

Operation

Warming up road paver and cleaning units

The warm-up time is approx. 20 minutes, press heating button [20].

Warning of crushing hazard

If the button [4] is pressed, conveyors, distribution augers and tamper start and can cause fatal injuries.

or

• Ensure there are no people

• Ensure the safety guards are fully fitted.

objects

in

the hazard area.

Switching on and off

conveyors/ distribution

augers/ tamper

» Press button [4].

./

Conveyors, distribution augers and tamper start.

./

The diode

in

the button illuminates.

» Press button [4] again .

./

Conveyors, distribution augers and tamper stop .

./

The diode

in

the button goes off.

BAL_1182_2063675_02_EN.doc

187

WIBTGEN

GROUP

"-...._/

~-

.•

Stopping road paver

Description/operation

Operation

~

Slowly place main drive switch [8] in position

./

The road paver is stationary and secured against unintentional rolling away/movement.

of

The stopping

the road paver is independent

P.

of

the operating mode.

Turning road paver

2.01.03

Laying

on

the

spot

(!:$

Ci)

pavement

Preconditions: main drive switch [8] is in position

~

Keep button

~

Move joystick [28] to left or right.

~

Regulate speed using the steering joystick [28] .

./

The road paver turns

~

Release switch [5] .

./

The road paver is stationary.

Warning

The rising and descending screed can cause fatal injuries.

• There must not be any people under the screed.

See booklet

[5]

pressed.

of

crushing hazard

on

paving.

in

the corresponding direction.

P.

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

189

Description/operation

Fig.

2.

163: Driving road paver using automatic steering system

Operation

99

MMI_DIS_001 k/045k/044k.jpg

Driving road paver using

automatic steering system

NOTE A safety feature prevents uncontrolled steering. The road paver stops if

[50] Steering trimming indication [53] Steering sensor error

[99] Switch

steering system.

on

or off automatic

indication

)>

Select paving operating mode using operating mode selector switch

[7].

)>

Switch on automatic steering system [99]

on

the operator's console

display .

./

The steering trimming indication (bar graph) [50] on the operator's console display start page changes to the steering sensor error indication (bar graph) [53].

)>

Adjust steering sensor to the middle of the bar graph. The bar graph indicates the automatic steering system's control

errors and at the same time is used to align the steering sensor with

the guide line.

)>

Main drive switch [8]

./

Road paver is operated using the automatic steering system.

the control error is greater than 20 mm and is not compensated within a distance

An error message

of

1-2

m.

is

also indicated on the operator's console display.

BAL_1182_2063675_02_EN.doc

191

WIRIGEN

GROUP

'.;_/

~-

.,

Description/operation

Operation

2.01.05.01

Raising/lowering and mechanically locking screed

Warning of crushing hazard

Retracting and extending parts moving up and down can cause fatal injuries.

• Ensure there are no people or objects

• Ensure the safety guards are fully fitted.

Risk of damage to the screed

The screed may sink and be damaged if

- You switch from the paving operating mode to another operating mode.

- The screed has been moved.

• Switch off screed float before you switch from the paving operating mode to another operating mode

Risk of falling

With the screed raised the first step can be more than 600 mm high. Risk

of

falling!

• When entering the machine, step carefully and hold on to the railing

with both hands.

• Never jump off the machine.

of

the machine or parts

in

the hazard area.

or

if the screed is moved.

of

the machine

Raise/lower screed

~

Unlock screed

~

Keep middle or bottom button [17] pressed .

./

The screed moves

~

Release middle

./

The screed remains in this position.

if

necessary.

in

the related direction.

or

bottom button [17] .

BAL_1182_2063675_02_EN.doc

193

Description/operation

Operation

2.01.06

Cleaning and shutting down road paver

Cleaning road paver

Hazard due to hot surfaces

Parts of the material hopper are very hot; there is a risk

• Wear personal safety equipment.

• If possible do not touch any parts

Warning of crushing hazard

Conveyors, distribution augers and tamper

the cleaning mode and can cause fatal injuries.

• Observe instruction labels on the road paver.

• Do not reach into rotating parts.

•

Do

not wear loose clothing

• Ensure the safety guards are fully fitted.

When working ground.

on

the open material hopper, park road paver on firm, level

or

jewellery.

of

the machine.

run

of

injury!

at moderate speed

in

To keep the road paver ready for use, it must be cleaned daily. On completion

be cleaned:

• Hopper

• Conveyors

• Conveyor base plate

• Distribution auger

• Front wall, frame (screed plate) and tamper (see screed operating instructions)

of

the paving work, the following parts of the machine must

on

the extending screed

Hazard due to substances damaging to the health

Bitumen and solvents contain substances that are harmful to the

health. The substances are present

• Do not inhale vapours.

• Wear personal safety equipment.

• Read and observe instruction in the related data sheets.

~

For bituminous mix, use bitumen solvent.

~

In

case

of

concrete paving, clean the parts of the machine given above with a water jet. Open bearings and grease nipples must not be directly subjected to the water jet.

in

the environment due to evaporation.

BAL_1182_2063675_02_EN.doc

195

GROUP

~

~-·

Description/operation

Operation

Shutting down road paver

Hazard due to full braking

In

case of incorrect operation there is a risk

• Prior to operating the main drive switch, move the control knob for paving speed to position

Hazard due to emergency stop

If the road paver is stopped using the emergency stop button,

- Mechanical parts are subjected to increased wear.

- Electrical and hydraulic components may be damaged.

• Only operate emergency stop button

• Do not use emergency stop button to stop the road paver normally.

0.

in

of

case

injury.

of

danger.

~

Place main drive switch [8]

~

Remove any mix still in the road paver.

~

Place operating mode selector switch

~

Set diesel speed adjustment [30] to MIN setting.

~

Switch off screed heating [20].

~

Switch off screed functions and all conveyor and compaction systems.

~

Lock hopper walls and screed.

NOTE Do not shut down engine immediately after operation at full load. Leave

to run at idle to allow time for temperature equalisation.

~

Switch off engine. Press start engine button [31] for approx. 2 seconds

until the engine stops.

~

Turn ignition key

~

Remove ignition key.

~

Pivot back pivoted out seat, check engagement.

../

The road paver has been shut down.

in

the ignition lock

in

position

P.

in

neutral position.

[7]

to position 0.

by

Joseph Vogele AG

BAL_1182_2063675_02_EN.doc

197

WIRTGEN

GROIJP

'-..;/

~-

•

Description/operation

Operation

Transporting

/loading

road

paver

Y Free machine or coarse soiling.

Y Secure all loose parts (e.g. boxes, trim panels).

~

Retract screed extending unit.

~

Remove screed extension (separate screed operating instructions).

~

Remove all attachments.

Y Retract direction indicators and lock.

~

Raise screed and lock.

Risk

of

falling

With the screed raised the first step can be more than 600 mm high.

Risk

of

falling!

on

• When entering the machine, step carefully and hold with both hands.

• Never jump off the machine.

Y Place distribution auger

~

Raise hopper walls and lock.

in

the highest position.

to the railing

Y Raise material deflector and secure.

Y Push Y Pivot

./

in

awnings and lock.

in

driver's seats completely and secure .

The road paver is prepared for loading.

NOTE

Driving/lashing road paver

on a low loader

NOTE Tie down screed to the means

The individual steps are described in the related sections.

~

Use strong loading ramps of sufficient width that are secured position.

Y Free loading ramps of soiling (e.g. oil, snow, ice).

~

Place anti-slip covering on loading ramps.

~

Observe maximum ramp angle allowed ( 15.6° front, 14 o rear).

~

Drive road paver up

in

a straight line.

Y Unlock screed and lower evenly onto the low loader.

Y Fold roof and secure.

Y If necessary, fold exhaust pipe forward using the handle.

Hazard due to hot exhaust pipe

The exhaust pipe

• Wear personal safety equipment.

• As far as possible, do not touch any part of the exhaust pipe.

~

Lash road paver and screed to the low loader.

./

The road paver has been driven onto a low loader and lashed.

equipment at the lashing points [2] provided.

is

very hot; there is a risk of injury!

of

transport using suitable lashing

in

©

2008

by

Joseph

V6gele

AG

BAL_1182_2063675_02_EN.doc

199

Description/operation

Operation

2.01.07.01

2

Locking hopper walls

Fig.

2.

3

1182~042.jpg

167: Hopper wall locking

[1] Locking clip [2] Handle

~

Raise hopper walls.

~

Pull locking clip [1] from the pin.

Y Push out pin [3]

The pin must be

~

Secure pin [3] with locking clip [1] .

./

The hopper walls have been locked.

in

the gate using handle [2].

in

the opening on the chassis.

[3] Pin

BAL_1182_2063675_02_EN.doc

201

WIRTGEN

GROVP

~-

"'-../

.•

Description/operation

Operation

2.01.07.03

Moving awning (option)

Fig.

2.

169: Moving awning

1182_045.jpg

Moving awning

NOTE The awnings must be retracted in the following situations:

[1]

Spring clip

);>

Undo spring clips [1] at front and back.

);>

Pull out awning.

);>

Lock awning using spring clips [1] .

./

The awning has been pulled out and locked.

• Transport

• Manoeuvring on the construction site

• Folded roof

BAL_1182_2063675_02_EN.doc

203

Switching traction drive to

free circulation

4

5

6

Description/operation

).>

Secure road paver against unintentional rolling away/movement.

).>

Shut down diesel engine.

).>

Undo hex socket head screws [1] on the two traction drive pumps

%of

a turn .

../

The traction drive has been switched to free circulation.

Releasing and activating brake

Operation

Releasing brake

Activating brake

1182_026.jpg

Fig.

2.171: Hand pump

[4] Hand pump

[5] Lever

).>

Secure road paver against unintentional rolling away/movement.

).>

Place ball valve [6]

).>

Insert lever [5]

).>

Release brake by pumping.

).>

Observe pressure indication on the pressure gauge [7].

in

vertical position.

in

the receptacle on the hand pump [4].

The hydraulics open at a pressure of more than

[6] Ball valve [7] Pressure gauge

30 bar. Under no

circumstances increase pressure to more than 40 bar.

).>

Remove lever (5) and insert

../

The parking brake has been released and the road paver can be

in

the holder.

moved as required.

).>

Tighten hex socket head screws [1] for the traction drive pumps.

).>

Place ball valve [6]

).>

Place main drive switch [8] Preconditions: there is no fault

../

The brake has been reactivated and the road paver secured against

in

horizontal position.

in

position

in

the hydraulics .

P.

unintentional rolling away/movement.

BAL_1182_2063675_02_EN.doc

205

WIBT,<tEN

GRO

~-

~

I

P

Description/operation

Operation

Scan quality bars (1)

The bars provide information more bars to be seen, the better the measured result. The information is based on the percentage point to the position with the "incorrect" points.

The image is 1 00%

Front<

Rear<

Front incorrect

Rear incorrect

Tab.

100%

2.2: Scan quality bars

on

the status of the measurements. The

of

"good" points. At a low percentage, arrows

©

2008

by

Joseph Vogele

AG

BAL_1182_2063675_02_EN.doc

207

Starting road scanner

Description/operation

Operation

Starting road scanner

Changing settings

NOTE Change setting when the machine is at standstill. Switching off the

~

Position screed

in

the correct position

on

the asphalt with

approximately the correct thickness using the tow point rams.

~

Continue working manually until the bar has stabilised.

~

Set ski length to the required value. There must not be any objects in the entire scan area, particularly at

the rear. If necessary, drive forward a little.

~

Press button [7] to set the height. If the laser scanner has been mounted at a different height compared to last time the system was used.

~

Adjust Niveltronic.

~

Switch Niveltronic to automatic.

v'

The road scanner has been started.

Changing settings

~

Switch off Niveltronic automatic mode.

~

Change the required RSS setting using the menu.

~

Re-adjust Niveltronic.

~

Switch Niveltronic to automatic mode.

v'

The settings have been changed.

system while the road paver is moving can degrade the evenness of the paving.

©

2008

by

Joseph

Vogele

AG

BAL_1182_2063675_02_EN.doc

209

WiffTGf;N

G!HlUP

~-

~

•

2.01.09.02 Laser receiver

Eagle

2XR

670

Description/operation

Operation

Good

(according to

data)

tech.

Geo-Laser

Laser-

Alignment/

Leica

Topcon

Spectra

I

Trimble

Quante

Geo

HL-63

LB

4

RL-H2S

RT

5SA,SB

Spectra

Laserlevel

Spectra

(SE, 1 E,

635

780

approx.

780

680

632,8

945

1145

2E)

Tab.

* Manufacturer's data

1

300m

)

2

l With laser power adjusted 250 m scanning range depending on laser

power set.

3

l Angular frequency can vary by up to 2Hz due to imprecise speed

regulation.

4

Occasional problems due to manufacturing quality; tolerance on the

)

deflector optics.

815

2.

5:

Laser transmitter

in optimal conditions

350

800

350

in

conjunction

1200

600

Inadequate, not

Good

with

LS-250

(according

m

even

to

tech.

200

Joseph

NOTE

Vogele

Values to be taken into consideration:

if

• Wavelength: greater than 670 nm,

• Angular frequency: not below already critical, ideal 20Hz.

• Scanning range: distances over 300 m generally involve, independent of

the scanning range that can be achieved, the problem

inaccuracies.

Device fluctuations due to beam diameter, the effect vibration.

AG

BAL_1182_2063675_02_EN.doc

possible in the invisible band.

10Hz

(600 rpm) on fast machines

of

wind and

increasing

211

Description/operation

Operation

2.01.09.03

2--i

Big ski

·--·---------------.,

:

i i

c.••IIMIIIJl}

Wiring I sensor assignment

!

I

i

Fig.

2.

17

4:

Big ski

1

2

NA_035.jpg

[1] Sensor connectors

[2] Standard CAN cable [3] Sonic ski CAN

[4] CAN cable with 2 x 120 R bus

terminating resistor

[5] Machine connecting cable,

analogue signal

BAL_1182_2063675_02_EN.doc

213

Detecting sensor

Description/operation

Operation

II

IIIII

011

F41

l~l

Fig.

2.

176: Detecting sensor

• The sensor connectors used are indicated by the LEOs for the sensor assignment [7] and

• Sensor constellations or error messages are also indicated on the display [6].

Acknowledging sensor

AI

on

the display [6].

I :2 3 I I

~~

SEn!

NA_036.jpg

If the big ski has been connected for the first time or the combination sensors changed, the sensor detection must be acknowledged.

The indication

Y Acknowledge sensor detection with any button .

./

The indication in the display [6]

Calibration setpoint

Prior to each pass the sensors must be re-calibrated to the reference (the analogue signal is set to 4V).

Y Press calibrate sensor button

./

Setpoint is calibrated .

./

"Set" is indicated

in

the display

on

the display.

[6]

flashes.

is

[1

0]

continuous.

.

of

BAL_1182_2063675_02_EN.doc

215

2.01.09.04 Ultrasonic sensor

Description/operation

Operation

2

NA_070.jpg

Fig.

2.

177: Ultrasonic sensor

[1] LED

Risk

of

damage to the machine

The

reference bail can get stuck and break.

• Be careful during operation. Ensure the reference bail doesn't get stuck.

The ultrasonic sensor has a sensing range recommended sensing range is 350 to 550 mm.

Within this range the status LED is continuously illuminated.

is outside the sensing range, the status LED flashes.

< 300 mm 300 to 350 350 to 550 550 to 600

> 600

Referecne bail error

mm mm mm

mm

with

working area

[2] Working area

of

300 to 600 mm.

flashes quickly

flashes slowly

illluminates

flashes slowly flashes quickly flashes quickly

The

If

the sensor

(10Hz)

(2

Hz)

(2

Hz) (10Hz) (10Hz)

by

Joseph Vogele AG

Tab.

2.9: Sensing range

BAL_1182_2063675_02_EN.doc

of

the ultrasonic sensor

217

Vogele AP-13 Operating Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual