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Track Paver

Titan 8820

Table of Contents
Track Paver Titan 8820
Identification Plate.....................................................................................................5
Technical Data Titan 8820.........................................................................................6
Dimensions Titan 8820 .............................................................................................7
Fuel, Oil and Lubricants ...........................................................................................8
Routine Maintenance.................................................................................................9
Inspection Intervals..................................................................................................10
Service Kits and Kits of Wearing Parts..................................................................11
Transport Weights ...................................................................................................12
Superstructure .........................................................................................................13
Connecting the control panel to the electrics .............................................................13
Air intake ....................................................................................................................14
Stowing the external control panels ...........................................................................14
Switch cabinet ............................................................................................................15
Allocation of the fuses ................................................................................................15
Batteries .....................................................................................................................16
Sun Roof ...................................................................................................................17
Sun Roof with Windscreen (Option)............................................................................18
Towing Arms, Continuous ........................................................................................19
Towing Arms, Split Version ......................................................................................19
Spacer Shims .............................................................................................................19
Screed Transport Lock ...............................................................................................20
Screed Spacer Blocks (Option) ..................................................................................21
Crawler Unit ..............................................................................................................22
Transmission oil..........................................................................................................22
Oil Change intervals....................................................................................................22
Maintenance................................................................................................................22
Road scrapers.............................................................................................................23
Idler wheel...................................................................................................................24
Hopper .......................................................................................................................25
Single sided operation ................................................................................................25
Conveyors .................................................................................................................26
Conveyor maintenance ..............................................................................................26-27
Conveyor chain tensioning .........................................................................................28
Conveyor drive chain tensioning ................................................................................29
Conveyor control switches .........................................................................................30
Augers .......................................................................................................................31
Auger maintenance ....................................................................................................31
Augers, mechanical height adjustment ......................................................................32
Augers, hydraulic height adjustment ..........................................................................33
Augers, extensions.....................................................................................................34

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Diesel Engine ...........................................................................................................35


Diesel engine maintenance .......................................................................................35
Engine oil drain plug ..................................................................................................35
Engine coolant ...........................................................................................................36
Preliminary fuel filter ..................................................................................................37
Fuel filter ....................................................................................................................37
Pump Distributor Gear ............................................................................................38
Pump distributor gear maintenance ...........................................................................38
Generator .................................................................................................................39
Drive belt tension ......................................................................................................39
Changing the generators drive belt ..........................................................................40
Electronic tension meter.............................................................................................41-42
Switch Cabinet ........................................................................................................43
Checking the safety device in the switch cabinet ......................................................43
Manual control of the heating system ........................................................................43
Automatic control of the heating system ....................................................................44
Operating the switches in the switch cabinet .............................................................44
Main Control Panel ..................................................................................................45
Manual Tow Point Control .........................................................................................46
Automatic Tow Point Control......................................................................................47
Hopper Wings Open / Close.......................................................................................48
Conveyors Control LH & RH.......................................................................................48
Conveyor Control ( Option ).......................................................................................49
Reversing the Conveyors ( Option )............................................................................49
Hydraulic Auger Height Adjustment............................................................................50
Auger Control LH & RH Sides.....................................................................................51
Overmodulating the LH/RH auger...............................................................................51
Auger Control when the Ultrasonic Sensors have failed.............................................52
Screed Lock & Screed Load Device Key....................................................................53-56
Switching on the screed load device on the main control panel..................................56
Screed Assist ( Option )...............................................................................................57
Seeting the pressure on the screed assist...................................................................57
Screed Floating Mode..................................................................................................58
Screed Raise / Lower...................................................................................................58
Screed Assist ( Option ) ..............................................................................................59
Screed Anti Climbing Lock........................................................................................60
Screed Tensioning Device VB-78/88 ( Option )...........................................................61
Tamper Control............................................................................................................62
Tamper speed..............................................................................................................63
Vibration MAN/AUTO...................................................................................................64
Screed Heating............................................................................................................65
Special Functions........................................................................................................66-69

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External Control Panels............................................................................................70


Positioning the external control panels........................................................................70
Conveyor Control in the External Control panels.........................................................71
Menu for auger control.................................................................................................71
Ultrasonic sensors for auger control............................................................................72
Central lubrication system........................................................................................73
Hydraulics...................................................................................................................74
Hydraulics, basics range..............................................................................................74
Changing the return line suction filter...........................................................................75
Tank ventilation filter.....................................................................................................76
Changing the tank ventilation filter...............................................................................76
Hydraulic oil Tank.........................................................................................................77
Changing the hydraulic oil............................................................................................78
Transport Control Panel.............................................................................................79
Operating the Paver if the I/O Module for the Travel Drive is Faulty......................80-81
Towing the paver when the Diesel engine is not running........................................82
Towing the paver............................................................................................................83
Jump starting the Diesel engine.....................................................................................84
Emergency Control.........................................................................................................85
Starting the Diesel engine Using the Transport Control Panel................................86
Menu for the Diesel Engine in emergency Control.........................................................87
Hopper Wings Open /Close, Transport control Panel....................................................88
Steering the paver with the Transport control Panel......................................................89
Drive Lever on the Transport Control Panel...................................................................90
Speed Potentiometer on the control Panel....................................................................90
Menu for the Screed Floating, Mode in emergency control...........................................91
Menu for levelling system in emergency control............................................................92
Tampers in emergency control......................................................................................93
Vibration control in emergency control...........................................................................94
Menu for the screed heating using the LH & RH external control Panels......................95
Allocation of Functions to the I/O Modules...............................................................96-100
Vario screed extension for VDT and MB screeds....................................................101-102
Additional Working Lights ( Option ).........................................................................103
Xenon Floodlights ( Option )......................................................................................103

Titan 8820

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Important; it is forbidden to make any


modifications to the paver.
The CE Declaration of Conformity
will become invalid if the
identification plate (2) is altered or
removed.
The CE Declaration of Conformity
only covers the paver and
equipment as it was on the day of
delivery by IR-ABG.

The identification plate (2) is riveted to the


RH side of the pavers frame (1) below
the seat console (please refer to chapter
1.15.2).
The identification plate serves the
purpose of identifying the paver and
contains the serial no., year of
manufacture, engine output, total weight
and dead weight etc.
Please quote the complete serial no. of
your paver when ordering spare parts.

Titan 8820

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Technical Data TITAN 8820

Engine (Diesel)

Make
Model
Output
Engine coolant
Fuel tank capacity
Emission classification

Paving
Output

Output (theor.)2
Mat thickness (max.)

Speeds

Paving
Transport

Crawler Unit

Length
Width (track plates)

Conveyor System

Hopper volume
Conveyors
Conveyor speed
Augers
Auger speed
Auger diameter

Paving Widths

min.
max.

kW/PS
l

t/h
mm

900
300

m/min
km/h

18
3.6

mm
mm

3085
325

1/min
mm

14
2
18.6
2
150
360

m
m

2.50
13.00

m/min

24 V electrical system

Electrical System
Transport
Dimensions

Width
Length
Height

Weight3

Basic paver

Deutz
BF6M 1013 ECP
179 / 243 @ 2200 1/min
Liquid
300
COM II / EPA II

mm
mm
mm

2500
6674
3077

kg

17500

Titan 8820

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Dimensions TITAN 8820

Titan 8820

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Fuel, Oil and Lubricants

Application:

Quantity:
17.5 litres (without filter)
Commencing
Serial No. 15428
19 litres (without filter)
Engine oil for the Diesel engine
19 litres (with filter)
Commencing
Serial No. 15428
21 litres (with filter)

Diesel fuel

approx. 300 Litres

approx. 190 Litres


130 Litres for oil changes.

2 x 3 Litres = 6 Litres
2 Litres
2 x 1.125 + 2 x 0.65 oil
drain hose = 3.8 litres
2 x 1 .0 = 2 litres

approx. 9 kg

Hydraulic oil for the


hydraulic system
The hydraulic oil must have a
purity of at least
the classification 19/ 17/ 14
according to ISO 4406:1999.
Transmission gears
Pump distributor gear
Conveyor drives
Auger drives
Lubricant for:
Vibrators
Tampers
Auger bearings
Conveyor bearings

Description:

Shell Rimula - Super SAE


15W/40
CPN: 13942032

CEN EN 590
DIN 51601
BS 2869: A1, A2
ASTM D975-88: 1-D, 2-D
NATO Code: F-54, F-75

Shell Universal Engine Oil


SAE 15/W40
CPN: 14830921

Shell Spirax MB 90
CPN: 13923131

Grease Shell Darina II


CPN: 13923115

Grease Shell Alvania R2


CPN: 14482509
Alternative: Grease Shell Darina II
CPN: 13923115

Remaining grease points

Coolant for the


Diesel engine's cooling system

Approx. 25 Litres

Titan 8820

Coolant (already mixed)


CPN 56246853

Routine Maintenance
Carry out the routine maintenance checks at 10 and 100 operating hours, as indicated or as required according to the instructions in this chapter. If the paver does not
reach the number of operating hours, then carry out the maintenance work at the time intervals specified.

10 Op. hrs
100 Op. hrs
500 Op. hrs
1000 Op. hrs

All routine maintenance work must also be carried out together with the service inspection intervals.

Chapter

Component

Maintenance work

Interval

Chapter

Component

1 Day
1 Month
6 Months
1 Year

Maintenance work

Interval
weekly

03
Crawler Unit

Road scrapers

Clean,
Check the condition

10

03
Crawler unit

Transmission gears

Check the oil level

05
Conveyors
06
Augers

Drive shaft
Left & right*
Auger drive case seals
Basic augers
Auger centre drive *
Auger outer bearings
Basic augers
Auger centre drive *

Lubricate
Check the condition
Lubricate
Check the condition

10

05
Conveyors
05
Conveyors

Drive chains

Check the condition

100

Conveyor drives

Fllstandskontrolle

100

Lubricate
Check the condition

Conveyor chains

Check the condition

100

Auger drives

Fllstandskontrolle

100

Auger centre bearings


Basic augers
Auger centre drive*
Auger outer bearings
Basic augers
Auger outer drives*
Auger centre bearings
Basic augers
Auger outer drives *
Auger centre bearings
At paving widths beyond 5.5 m
Engine oil

Lubricate
Check the condition

10

Drive chains
Centre auger drive

100

Lubricate
Check the condition

10

06
Augers

Bearing protectors,
centre auger drive

Check the condition


Check and adjust the
tension
Check the condition

100

Lubricate
Check the condition

10

06
Augers

Auger drive case

Drain off the water

1000

Lubricate
Check the condition
Check the oil level

10

Pump distributor gear

Check the oil level

100

10
10

Batteries,
Connections
Air filter

Check the water level


Tighten the terminals
Check the condition
Clean

100

Functional test

07
Diesel engine
10
Electrics
07
Diesel engine

Check the oil level

10

07
Diesel engine

Coolant level

As required

As required

06
Augers

06
Augers
06
Augers
06
Augers
06
Augers
07
Diesel engine
08
Control panel
09
Hydraulics
11 Outrigger
for grade
control
12 Central
lubrication

Warning devices (Horn,

warning lamps on the external


distributors on Vario screeds).
Hydraulic oil

10

10

When
indicated
When
indicated

Outrigger tube surfaces

Lubricate

10

01
Superstructure

Sieve in the fuel filler neck

Check the coolant


level and
concentration
Clean

Grease container

Check the grease level

10

01
Superstructure
01
Superstructure
03
Crawler unit

Emulsion spraying system,


sieve in the tank filler neck
Sun roof

Clean

Lubricate

100

Idler wheel

Lubricate

500

* These grease points will be automatically lubricated if the paver is equipped with the

optional central lubrication system.

05
Conveyors
06
Augers
06
Augers

OM-MM Titan 8820

03.2004

Inspection Intervals
Chapter

Component

Maintenance work

02 Frame

Apply grease

03 Crawler unit

Spacer shims, slip guides and guide


rollers for the towing arms
Transmission gear oil

Change the oil

05 Conveyors

Conveyor drive gear

Change the oil

2000

06 Augers

Auger drive gear

Change the oil

2000

07 Diesel engine

Engine oil
(depending on paver application)
Engine oil filter cartridge
(depending on paver application) Refer to
engine manufacturers documentation
Fuel filter / preliminary fuel filter cartridge
Refer to engine manufacturers
documentation
Air filter cartridge. Refer to engine
manufacturers documentation

Change the oil

500

Change the filter

500

Change the filter

1000

Change the filter

Safety cartridge. Refer to engine


manufacturers documentation

Change the filter

V-belts

Check and tension

Change after the


cartridge has been
cleaned 3 times
Change after the
cartridge has been
cleaned 5 times
Change as required

07 Diesel engine

Engine coolant

Change the coolant

07 Diesel engine

Concentration of engine coolant

Check the concentration

07 Diesel engine

Check for leaks and tight fitting

07 Diesel engine

Cooling system, clamps on the hose


connections
Oil in pump distributor gear

Change the oil

07.Generator

Drive belt

Check the tension

07.Generator

Drive belt

Change the drive belt

09 Hydraulics

Tank ventilation filter

Change the filter

1000

09 Hydraulics

Hydraulic oil

Change the hydraulic oil

1000

09 Hydraulics

Return line filter RKM/ RF

Change the filter

09 Hydraulics

Breather valve, pump distributor gear

Clean

Div. chapters

Connecting bolts on all hydraulic


cylinders

Check for wear and tight fitting

07 Diesel engine

07 Diesel engine

07 Diesel engine

07 Diesel engine

07 Diesel engine

10

OM-MM Titan 8820

100

500
X

1000 1500 2000 2500 3000 3500 4000 4500 5000


X

2000

500

1000

X
X

1500
X

03.2004

500
3000

As indicated on the
control panel
2000

X
X

500

2000

X
X

X
X

X
X

X
X

Further Intervals

1000

Road Development Hameln

Service Kits and Kits of Wearing Parts

Chapter

Assembly

Wearing Parts Kit CPN

03

Rubber Track Pads

14312714

05

Conveyors
Hopper Floor Plates
Conveyor Chain Covers
Chains

56280803

06

Augers
Auger Flights
Screws

56261241

CPN
EPM Diagnosing Kit
80623044
Service Kit

CPN
Service Kit
Service Kit, extended
range

80688088
80688096

Always quote the model and serial number of your paver when ordering spare parts.

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Titan 8820

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Transport Weights

The following weights refer to the paver with the screed in the paving width indicated
and are approximate weights without options.
Titan 8820
VB-78
VB-78

5.0 [m] = 20.98 [t]


9.0 [m] = 24.03 [t]

VB-88
VB-88

6.0 [m] = 21.52 [t]


9.0 [m] = 23.95 [t]

VB 89 ETC*
VB 89 ETC*

3.0 [m] = 21.82 [t]


6.0 [m] = 24.25 [t]

VDT-V-78
VDT-V-78

5.0 [m] = 21.35 [t]


9.0 [m] = 24.63 [t]

VDT-V-88
VDT-V-88

6.0 [m] = 21.70 [t]


9.0 [m] = 24.43 [t]

VDT-V-88 ETC*
VDT-V-88 ETC*

3.0 [m] = 21.94 [t]


6.0 [m] = 24.67 [t]

VDT-121
VDT-121

2.5 [m] = 19.50 [t]


9.0 [m] = 24.40 [t]

MB-122
MB-122

2.5 [m] = 19.10 [t]


10.0 [m] = 23.70 [t]

* = only available as ETC version, articulated screed extension + 10%

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Superstructure
Control Panel Support
Connecting the panel to the electrics:
The paver's ignition must be switched
off when connecting the control panel
to the electrics.
Connect the power supply cable (10)
located on the support (1) to the
socket on the rear side of the control
panel (3).
Engine Bonnet LH & RH

Storage Cabinet for Control Panel

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Titan 8820

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Air Intake
The air intake grill is located above the
RH side door. The combustion air for the
Diesel engine is drawn in through the air
intake as well as some of the air for
cooling the upper section of the radiator.
The hot air from the engine compartment
escapes through an exit grill. A storage
compartment is integrated in the air
intake in which the external control
panels, the first aid set and the paver's
documentation can be safely stowed.
Stowing the External Control Panels:

Six holes (5) are located on the LH


inside of the storage compartment (2)
for slotting in both external control
panels.
Secure the external control panels in
the storage compartment using the
wing screws taken from the control
panel supports on the screed.

Fuel Tank

14

Titan 8820

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Fuses:

The fuses are located in the grey switch


cabinet on the LH side of the steps to the
operator's platform.

Open the switch cabinet.


Switch off the paver's ignition before
changing any fuses. Remove the faulty
fuse and insert a new fuse with the same
amperage.
Allocation of the fuses
Please refer to the RH plan.
(Similar to the illustration)

15

Titan 8820

Road Development Hameln

Batteries

The batteries are installed on the RH side


of the paver.
The battery master switch (1) is installed
on the paver's RH frame side.
With the battery master switch (1), the
entire current supply to the paver can be
switched off.
The main fuse (2) is located inside the
paver's RH side door (please refer to
chapter 01.04).
The batteries (3) are located behind the
RH operator's seat.

16

Titan 8820

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Sun Roof
Remove the jointed pump lever (7) from
its bracket (8).
Fold the jointed lever (7) out to make a
straight tube.
Slide the ferrule (9) on the pump lever (7)
onto the joint (10) to make a rigid
connection.
Raise the sun roof by swinging the pump
lever (7) up and down.
The sun roof (1) has reached its raised
end position when a noticeable resistance
is felt on the pump lever(7).
Now place both locking bolts (2) through
the lower holes (3B) on the rear roof
supports (4).
The sun roof is now safely secured in the
raised position.
Now switch the pump to the "Roof Lower"
position and relieve the pressure on the
hydraulic cylinder by swinging the pump
lever for a further two complete strokes.
Fold the pump lever (7) together and
return it to the pump lever bracket (8).
Thereafter, the switch lever (6) on the
pump (5) must be switched to the LH
position.
You can now climb up onto the operator's
platform.

Hand pump for roof; grease nipple


hinge joint on roof support

Check the function of the hand pump (1)


once a month.
Oil change intervals:
Every 2000 hours or every 2 years
whichever occurs first.
Oil:
Shell Universal Engine Oil SAE 15W40.
Hinge joints (6) RH & LH side:
Lubricate: monthly
Lubricant: grease Shell Darina 2

17

Titan 8820

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Sun Roof with Windscreen ( Option )

The windscreen (1) protects the


operator from rain and strong winds

Caution, Danger of Crushing !


The sun roof must be lowered for
transport. The windscreen is vertically
divided into two halves which must be
closed for transport.

Opening the Windscreen:


LH Side
Release the centre threaded type
window catch (2).
Release the outer threaded type
window catch (2).
Push the bottom of the windscreen
outwards towards the hopper.
The windscreen will be held in position
by the gas springs.
RH Side
Release the centre threaded type
window catch (2).
Release the outer threaded type
window catch (2).
Push the bottom of the windscreen
outwards towards the hopper.
The windscreen will be held in position
by the gas springs.

18

Titan 8820

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Towing Arms, Continuous


Lubricant:
Grease Shell ALVANIA R2,
CPN: 14482509
Quantity:
Grease the guide rollers (1) until lubricant
emerges from the cavities.
Grease the slip guides (2) for the towing
arms as required.
Intervals:
500 operating hours or every 6 months.
Grease points:
Grease the guide rollers (1) on the towing
arms.
Clean and grease the slip guides (2).
Towing Arms, Split Version ( Option )

Spacer Shims (3)

Lubricant:
Grease Shell ALVANIA R2,
CPN: 14482509
Quantity:
As required.
Intervals:
500 operating hours or every 6 months.

Towing Arms, Split Version ( Option )

Grease points:
Ensure that grease is applied to the LH
and RH spacer shims (3).
Clean the spacer shims before applying
grease.

19

Titan 8820

Road Development Hameln

Screed Transport Lock


The screed transport lock is a manually
operated and mechanical locking device.
The towing arms (4) rest in the hooks (3)
and secures the screed against lowering
during transport. Furthermore, the screed
transport lock relieves the pressure from
the transport cylinders (5)..

Safely securing the screed in the


transport lock:
Raise the screed with the screed
transport cylinders (5) as far as it will go
and move both LH and RH levers (1)
downwards into the notches (2). The LH
and RH spring loaded hooks (3) will
extend outwards to take up the LH and
RH towing arms (4).

20

Titan 8820

Road Development Hameln

Screed Spacer Blocks 50 [mm] ( only


available as an option with split towing
arms)
Screed spacer blocks are used for paving
thicker mats to increase the depth of the
auger channel.

Installing the screed spacer blocks:


Completely lower the screed to the
ground. Remove the 5 standard bolts
(3) from the flanges (2). Drive the
paver forward by approx. 60 mm.
Insert the 2 spacer blocks between
the flanges (2). Insert the 5 longer
bolts (3) and tighten them up.
Removing the screed spacer blocks:
Completely lower the screed to the
ground. Remove the 5 long screws
from the flanges (2). Drive the paver
forward by approx. 10 mm. Remove
the spacer blocks from between the
flanges (2). Reverse the paver by
approx. 70 mm. Insert the 5 standard
screws (3) and tighten them up.

21

Titan 8820

Road Development Hameln

Crawler Unit

Maintenance of the Transmission


Gears

Transmission oil:
Shell Spirax MB 90
CPN 13923131
Quantity:
6 l = 3 l for each transmission gear
Intervals:
Oil change:
First oil change at 100 operating hours,
thereafter once a year or every 1500
operating hours at the latest.
Maintenance:
Weekly: Visual check, check for unusual
noises, check the oil level.
Monthly: Check all threaded connections
(observe the torques specified in the
assembly drawing).

Checking the oil level in the LH and RH


transmission gears:
Remove the cover plate (A).
Park the paver on level ground.
The oil level plug (5) is in the horizontal
position.
Unscrew and remove the oil level plug
(5).
Unscrew and remove the oil filling plug
(6).
The oil level must reach the lower edge of
the threaded hole for the oil level plug (5)
(the oil level is then correct).
Top up with transmission oil if the oil level
is too low.
Replace and tighten the oil level plug (5)
and the oil filling plug (6) after checking
the oil level.
Replace the cover plate (A).

22

Titan 8820

Road Development Hameln

Crawler Unit
The LH and RH crawler units (1) are
connected to the basic frame. The
crawler tracks are fitted with durable
rubber track pads. As soon as the Diesel
engine is started, the crawler tracks are
automatically tensioned by the hydraulics
and kept continuously tensioned.

Road Scrapers
The road scrapers are mounted in front of
the LH and RH crawler tracks. The road
scrapers are lowered for paving work.
The road scrapers are used for clearing
away obstacles in front of the crawler
tracks such as paving material which
dropped out of the hopper. Obstacle
would cause an alteration in the mat
thickness and this would reduce the
paving quality.

23

Titan 8820

Road Development Hameln

Idler Wheel, Maintenance

Grease points:
Lubricate the grease nipple (8) on the
idler wheel bearing on the front LH and
RH crawler unit.
Slowly drive the paver forwards or
reverse until the grease nipple on the
idler wheel bearing has reached a
position where you can apply the grease
gun..

Lubricant:
Grease Shell ALVANIA R2.
CPN 14482509
Quantity:
Apply grease until it emerges from the
cavities.
Intervals:
Every 500 operating hours..

24

Titan 8820

Road Development Hameln

Hopper

The hopper (1) consists of a LH and RH


hopper wing (2 & 3) which are mounted
on the paver's basic frame (4). The
hopper serves as a bunker for the paving
material during paving work. The hopper
wings (2 & 3) can be closed for transport
or to completely empty the hopper. The
hopper wings must be opened for the
dump truck to charge the hopper.

Single Side Operation (Option)


With the single side operating feature, the
hopper wings (2 & 3) can be individually
opened and closed.

25

Titan 8820

Road Development Hameln

Conveyors

Conveyor Maintenance
Lubricant:
Grease Shell DARINA II,
CPN: 13923115
Quantity:
Apply grease until it emerges from the
cavities.
Intervals:
Every 10 operating hours or once a day.
Grease points:
1 grease nipple on the LH idler wheel (2)
and 1 grease nipple on the RH idler
wheel (3). The inside bearings will be
lubricated at the same time
The LH and RH outer bearings for the
drive shaft (4 & 6).
The centre bearing for the drive shaft (5).

If the paver is equipped with the optional


central lubrication system, all conveyor
bearings will be automatically greased.
Press the operating key for "lubrication"
at the end of the day's paving work.

26

Titan 8820

Road Development Hameln

Conveyors
The conveyors (1) are centrally mounted
between the hopper wings. The conveyor
system consists of two separate bar
conveyor chains. Each conveyor chain is
individually controlled.

27

Titan 8820

Road Development Hameln

Conveyor chain adjustment:


The conveyor chains (7) must be
tensioned if they sag more than 100 mm
in a cold condition.
The conveyor chains are correctly
adjusted when the lower edge of the
paver's frame (8) is flush with the lower
edge of the conveyor chain (7).

Tensioning the conveyor chains:


Loosen the locking nuts (9) (2 nuts per
conveyor chain).
Tension the LH and RH conveyor chains
equally with the tensioning nuts (9)
located below the front cross beam.
Both conveyor chains should sag by
approx. 50 - 70 mm in a cold condition.
After tensioning the conveyor chains,
secure the tensioning nuts with the
locking nuts.

The conveyor chains should be replaced


when they have elongated so far that it is
not possible to tension them with the
conveyor tensioning device.
Never remove any links from an
elongated chain to achieve the correct
tension. The toothed drive wheels will be
prematurely damaged by the wrong link
spacing.
Regularly check the conveyors, drive
wheels and idler wheels for wear.
New conveyor chains must be installed in
such a way that the scraper on the LH
chain is on the outer LH side and the
scraper on the RH chain is on the outer
RH side.

28

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( Similar to the illustration )

Road Development Hameln

Conveyor drive chain adjustment


The slackness on the drive chain should
not exceed 10 mm as illustrated. This is
easy to check by pressing the middle of
the long chain side with a screw driver.
The drive chain must be tensioned if it
can be depressed by more than 10 mm.
Tensioning the conveyor drive chains
(the same procedure applies to both LH
and RH sides):
Loosen the lock nut (11) on the
tensioning screw (10).
Loosen the four screws (12) on the
mounting plate for the hydraulic motor.
Turn the tensioning screw (10) clockwise
until the conveyor drive chains can be
depressed by approx. 5 mm with a
screwdriver.
Lock the tensioning screw (10) with the
lock nut (11).
Tighten up the four screws (12) on the
mounting plate for the hydraulic motor.

The conveyor drive chains should be


replaced when they have elongated so far
that it is not possible to tension them with
the tensioning device.
Never remove any links from an
elongated chain to achieve the correct
tension.
Regularly check the conveyor drive
chains and toothed drive wheels for wear.
Spray a suitable chain lubricant on the
drive chains.

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Conveyor Control

The paddle type switches (18) are located


on either side of the auger drive case on
the rear of the paver. The paddle type
switches continuously control the amount
of material conveyed by the conveyors.

Adjusting the paddle type conveyor


control switches
Too much material in the auger channel
Push the levers on the paddle type
switches towards the paver's rear wall.
Not enough material in the auger channel
Pull the levers on the paddle type
switches away from the paver's rear wall.

The conveyor control is correctly adjusted


when the augers are submerged by
approx. 2/3 in the paving material.

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Augers
Auger Maintenance
Lubricant:
Grease Shell DARINA II,
CPN: 13923115
Quantity:
Apply grease until it emerges from the
cavities.
Intervals:
Every 10 operating hours or once a day.
Grease points:
Three grease nipples (3) for the centre
auger bearing and auger case seal.
One grease nipple (4) on each of the
auger outer bearings..

Checking the bearing protectors


Check the bearing protectors every 100
operating hours or once a month.
Clean the bearing protectors with a
cleaning solvent to check them and
before fitting new parts.
The bearing protectors prevent dirt and
paving material from penetrating the
bearings. Regularly check these parts
and renew them if necessary.

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Mechanical Auger Height Adjustment


The mechanical auger height adjustment
is the standard version supplied with the
paver.
With this feature, the height of the augers
can be mechanically adjusted.

Raising/lowering the augers on the basic


paver (without auger outer bearings):
Unscrew and remove the threaded
bolt (A) from the rear wall if it is fitted
on your paver.
By turning the barrel nut on the
turnbuckle (6), you can raise or lower
the augers over a distance of + - 50
mm from the zero position.
If fitted to your paver, replace the
threaded bolt (A) in the rear wall (the
locating holes are at distances of + 50
mm and 50 mm from the zero
position).

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Hydraulic Auger Height Adjustment


The hydraulic auger height adjustment is
available as an option. As opposed to the
standard version, the height of the augers
can be easily and quickly adjusted by the
hydraulic cylinder (1).

Raising/lowering the augers on the basic


paver (without auger outer bearings):
Unscrew and remove the threaded
bolt (A) from the rear wall if it is fitted
on your paver.
Use the switch (2) on the main
distributor to raise or lower the augers
with the hydraulic cylinder (1) over a
distance of + - 50 mm from the zero
position.
If fitted to your paver, replace the
threaded bolt (A) in the rear wall (the
locating holes are at distances of + 50
mm and 50 from the zero position).

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Auger Extensions ( Option )

34

Adjust the turnbuckle on the horizontal


brace (3) to bring the auger channel
plate in alignment with the paver's rear
wall.
Use the vertical brace (7) to connect
the auger channel plate (4) to the
paver's upper connecting lug. Secure
the brace with the connecting bolts
and safety clips (6 & 8). Adjust the
turnbuckle on the vertical brace (7) so
that the auger channel plate is at an
angle of 90 to the paver's side wall.
Push the auger extensions (20) onto
the basic auger.
Ensure the pitch of both basic auger
and auger extension is the same.
Connect both coupling pieces (11)
with the screw (10) and fit a 140
auger flight (9) if required.
Fit the bearing arm (18) with the
screws (19) to the support plate (17).
The auger extension must be set in
the same height as the basic auger.
Chapters 06.04 and 06.05 describe
the height adjustment of auger
extensions fitted with auger outer
bearings.
Fit the end cap (15) with a screw to
the end of the auger extension shaft.
A 140 auger flight (16) can be fitted
with an M20 x 140 screw to improve
the distribution of the paving material.
Fit the hinged end plate (14) to the
bracket (13) using the screws (12) as
illustrated.
Ensure that all protective guards (21)
are correctly fitted and that they are
not damaged.

Titan 8820

Road Development Hameln

Diesel Engine
Maintenance

The engine manufacturer's handbook


supplied with the paver contains
instructions on the following engine
maintenance points:

Engine oil
Engine oil filter
Preliminary fuel filter (EPM diagnosing
and control system)
Air filter (EPM diagnosing and control
system)
Cooling system
V-belts
Tappet clearance
Alternator

Engine oil drain plug:


The engine oil drain plug (2) is located on
the LH side of the paver.
Please refer to the engine manufacturer's
handbook for the procedure for changing
the engine oil.
Always fit new sealing rings to the drain
plug after changing the engine oil..

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Engine Coolant
Checking and topping up with engine
coolant:
Open the service hatch on the top RH
side of the superstructure to check the
engine coolant.
Remove the filler on the compensator
reservoir (3) and top up the system with a
suitable coolant.
Instructions for topping up the cooling
system are contained in the engine
manufacturer's handbook
Draining off the engine coolant:
Open the RH side door. Use a suitable
container for catching the coolant when it
is drained off.
Unscrew and remove the threaded drain
plug (4) from the radiator and immediately
connect the hose (5) to the drain point.
The hose (5) is contained in the tool kit
supplied with the paver. Remove the filler
cap (3) from the radiator so that the
coolant can quickly drain off. After the
radiator is completely empty, remove the
hose (5) and replace the threaded drain
plug (4). Use new seals when replacing
the connection.
Cleaning the engine radiator:
Open the RH side door. Clean the
radiator as and when required and
remove all dirt and leaves etc.
Thereafter, close the RH door..

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Preliminary fuel filter

Filter cartridge (11) and filter insert (12)


Filter change intervals
First filter change at 100 operating hours.
Thereafter every 1000 operating hours or
once a year.
Open the drain plug (14) to drain the
water out of the preliminary filter every
100 operating hours or once a month.
By using the hand priming pump (16) the
filters (11 & 12) can be quickly filled with
Diesel fuel after a filter cartridge (11) or
filter insert (12) change.

Fill the filter cartridge (11) and the filter


insert (12) with Diesel fuel using the hand
pump before installing them.
Fuel filter:

(13) = Electr. Condensation water


indicator

Please refer to the engine manufacturer's (15) = Breather screw


handbook.
(17) = Stop cock in the fuel supply line

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Pump Distributor Gear

Transmission oil:
Shell Spirax MB 90
CPN 13923131
Quantity:
2 litres
Intervals:
Check the oil level every 100 operating
hours or once every 14 days.
First oil change is due at 100 operating
hours.
Thereafter change the oil every 1500
operating hours or at least once a year.
Visual check:
Visually check the pump distributor gear
daily for oil leaks.
The vent filter (8) must be cleaned every
1000 operating hours but at least once a
year.
(7) = Oil filler cap
(10) = Oil drain plug

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Generator
Maintenance:
Mechanically pre-adjusting the initial
drive belt tension

The tensioning pulley (4) ensures a


constant and uniform tension on the drive
belt (3).

The tension on the drive belt (3) must be


checked during the first inspection (at 100
operating hours) and thereafter every 500
operating hours. The drive belt must be
renewed every 3000 operating hours or
once every three years.

Adjusting the generator:


Measure the distance between the drive
belt pulleys.
If this distance is not 704 1.5mm, you
must carry out the following procedure.
Loosen all four screws ( 5) on the
generator console(6). Measure the
distance between the outer surfaces of
the drive belt directly across the pulleys.
Keep adjusting the drive belt tension until
the distance is 704 1.5 mm. Thereafter,
tighten up the four screws (5) on the
generator console.

After adjusting the initial drive belt


tension, the tension must be measured
once again with an electronic tension
meter.

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Changing the generators drive belt


Fitting a new drive belt:
Preparation:
Check all screws and the adjusting
screw for easy movement and apply
shifting oil if necessary.
Fitting & tensioning the new drive belt:
Push the new drive belt (3) through
the air intake opening (14). Then
reach through the air intake opening
and place the drive belt on the
generator pulley.
Thereafter, place the drive belt on the
drive pulley on the Diesel engine.
Turn the tensioning screw (13)
clockwise until the distance between
both drive belt pulleys is 704 + 1.5
mm. Ensure the drive belt remains
correctly seated on the pulleys when
turning the tensioning screw.
The new drive belt is now pretensioned.
Securing the generator:
Tighten up the four screws (5) to
secure the generator on the console
(6).
Tensioning the tension pulley (4):
Turn the screw (11) clockwise until the
pulley (4) is tensioned.
Check the drive belt tension with the
electronic tension meter as described
in chapter 7.10.01.
After reaching the correct tension of
0047 Hz, tighten up the lock nut (12).

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Electronically measuring the drive belt


tension:

By tapping the generator's drive belt (3)


with the grip of a screwdriver, it will be
made to vibrate. These vibrations can be
measured with an electronic tension
meter which displays the result of the
measurement in hertz (Hz).
The ABG part number for the tension
meter is 54542469
Switch on the tension meter (10) with the
ON/OFF button (8). Keep the ON/OFF
button pressed and the charge in the
battery will be displayed in mV. Minimum
charge: 0680. Release the button (8) and
if FebA appears after the self test, the
battery has not sufficient power. In this
case, the tension meter will switch itself
off. Release the button and if 0000
appears after the self test, the tension
meter is ready for use. Hold the sensor
head (7) approx. 10 to 20 mm above the
centre of the belt to be measured. A red
light spot will indicate the position of the
sensor.
Important:
The sensor head must be held parallel to
the drive belt. Tap the belt to make it
vibrate. An acoustic signal will sound if
the measurement has been made
successfully. The frequency of the
vibrations will appear in the display on the
tension meter.
The drive belt is correctly tensioned if the
value of 0047 (Hz 2) appears in the
display.

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Measuring errors are indicated by 0000


or a blank display.
The drive belt was not tapped hard enough
or, too much distance between the sensor
head and the drive belt or, there were
unfavourable surrounding light conditions or,
the sensor head was dirty.

Drive Belt:
Too much tension: Loosen the four screws
(5) on the generator console and loosen the
tensioning screw (13) by a few turns. Tighten
up the four screws on the generator console.
Now measure the tension on the drive belt
with the tension meter once again. If the
permissible value has not been reached,
repeat the above procedure until this value is
reached.
Not enough tension: Loosen the four screws
(5) on the generator console and tighten the
tensioning screw (13) by a few turns. Tighten
up the four screws on the generator console.
Now measure the tension on the drive belt
with the tension meter once again. If the
permissible value has not been reached,
repeat the above procedure until this value is
reached.
Tensioning pulley:
Too much tension: There is too much tension
if the tensioning pulley depresses the drive
belt (3) by more than 20 mm.
Loosen the lock nut (12) and unscrew the
tensioning screw (11) by a few turns.
Now tighten up the lock nut (12).
Now measure the tension on the drive belt
with the tension meter once again.
If the permissible value has not been
reached, repeat the above procedure until
this value is reached.
Not enough tension: There is not enough
tension if the tensioning pulley depresses the
drive belt by less than 10 mm.
Loosen the lock nut (12) and screw in the
tensioning screw (11) by a few turns.
Now tighten up the lock nut. Now measure
the tension on the drive belt with the tension
meter once again. If the permissible value
has not been reached, repeat the above
procedure until this value is reached.

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Switch Cabinet
The door (9) on the switch cabinet must
remain open during paving operation so
that the paving crew can observe the
green control lamps (2), (3) and (4), the
red warning lamp (7), access the
switches (2), (3) and (4) and hear the
warning horn (8).
By pressing the button switch (5) / (Test)
you can check the insulation control
integrated in the switch cabinet.
This will simulate a short circuit, for
example between a wire in the power
supply and the steel screed. The short
circuit will be indicated visually by the red
warning lamp (7) and acoustically by the
warning horn (8).
Manual control (emergency control):
If a short circuit occurs, the insulation
Switching to manual control:
control will switch on the red warning
Switch to manual control if the
lamp and sound the warning horn
automatic mode fails.
Turn the switches (2), (3) & (4) one
Checking the safety device in the
after the other by 90 to the right (Start
switch cabinet:
position).
(heating system)
Release the switch as soon as the
green warning lamp for that particular
Check the insulation control daily
circuit lights up.
before starting work with the paver.
The switch will automatically return
Before starting the Diesel engine,
and lock in the Hand position at 45 to
check the connections in the power
the right.
supply for correct fitting and tightness.
Simulate a short circuit in the system The speed of the Diesel engine will
automatically increase to 1400 1/min.
by pressing the test switch (5) to
trigger off the red warning lamp (7)
Switching off the manual control:
and sound the warning horn (8).
Turn the switches (2), (3) & (4) one
After the test has been completed,
after the other by 45 to the left to the
press the cut-out switch (6) to stop the
neutral (O) position.
warning horn (8).
After switching to this position the
green warning lamps (2), (3) & (4)
must extinguish.

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Switch Cabinet

Then switch off the Diesel engine to


extinguish the red warning lamp (7).
Now start the Diesel engine again and
if the red warning lamp does not
extinguish and the warning horn
continues to sound, there is a fault in
the system. Faults in the system may
only be repaired by a fully trained,
qualified and authorized electrician.
Closely observe your locally prevailing
laws and directives.
Training courses for electrically
Automatic screed heating mode:
heated paving screeds can be taken
(Standard operation):
at IR-ABG's Training Centre in
Hameln.
Switch on the electric heating using the
operating keys on the main control panel
as described in chapter 08.
Switching to the automatic mode:
Operating the switches in the switch
Turn the switches (2), (3) & (4) one
cabinet:
after the other by 45 to the left
The Diesel engine must be started to
(AUTO).
operate the electric heating.
The green warning lamps (2), (3) & (4)
The switches (2), (3) & (4) for the 3
indicate the operating status of the
heater circuits have 4 switching
three heater circuits.
positions:
If a green warning lamp lights up, it
means that the particular circuit is
45 to the left = Automatic (AUTO)
being heated.

Centre
= Neutral (0)
If the green warning lamp
45 to the right = Hand
extinguishes, it means that the pre-set
90 to the right = Start
temperature has been reached and
the circuit is no longer being heated..
If the temperature falls below the preset value, the heating for that
particular circuit will be automatically
switched on again.
Switching off the automatic mode:
Turn the switches (2), (3) & (4) one
after the other by 45 to the right
(Neutral position).
After switching to this position the
green warning lamps (2), (3) & (4)
must extinguish.

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Main Control Panel


All operating keys and control elements
must be free and easily accessible.
Never operate more than one key or
control element at the same time which
actuates a contrary function on the paver.
Never operate the keys on the control
panel with a pointed or sharp edged
object as this will damage the clear
plastic cover. Use spirit to clean the clear
plastic cover.
Switch off the ignition before connecting
or disconnecting the main control panel to
or from the paver's electrical system.

45

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Road Development Hameln

Manual Tow Point Control


LH & RH sides, Operating Keys
S113/S114/S115/S116
By adjusting the tow points, the screed's
angle of attack and consequently the mat
thickness will be altered. The LH and RH
tow points can be independently adjusted
by pressing separate operating keys. The
tow points can be adjusted manually by
the operator or automatically by a
levelling system installed on the paver
(please refer to chapter 08.01.30).
Raising the LH tow point:
Press the key S113 and keep it pressed
until the required position has been
reached.
Lowering the LH tow point:
Press the key S114 and keep it pressed
until the required position has been
reached.
Raising the RH tow point:
Press the key S115 and keep it pressed
until the required position has been
reached.
Lowering the RH tow point:
Press the key S116 and keep it pressed
until the required position has been
reached.

Position of the levelling cylinders:


When paving, never run the levelling
cylinders and consequently the tow points
up against their upper or lower limit stops.
The system does not function in this
position and a levelling is not possible.

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Automatic Tow Point Control


Menu for the Levelling System Key
S111, ON / OFF Key S112
Recommended Switching Positions:
Press the key S151 AUTO for paving
work. This will ensure that the position of
the tow points is not altered when the
paver comes to a standstill.
The operating key AUTO does not refer
to the levelling system but to the
automatic tow point control by the drive
lever S24.
Position of the levelling cylinders:
When paving, never run the levelling
cylinders and consequently the tow points
up against their upper or lower limit stops.
The system does not function in this
position and a levelling is not possible.
By adjusting the tow points, the screed's
angle of attack and consequently the mat
thickness will be altered. The LH and RH
tow points can be independently adjusted
by pressing separate operating keys. The
tow points can be adjusted manually by
the operator or automatically by a
levelling system installed on the paver.
Operating the Menu:
Function AUTO:
Press the key S151 and the tow points
can only be adjusted when the paver is
moving forwards, i.e. the drive lever S24
is in the forward position.
Operating the Menu:
Function MAN:
Press the key S150 and the tow points
can be adjusted whatever the position of
the drive lever S24.

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Hopper Wings Open / Close, Keys


S107 S110
Open the hopper wings by pressing the
keys S107 or S110.
Close the hopper wings by pressing the
keys S108 or S109..
Hopper Wings Open / Close Separately
Keys S107/S108/S109/110 (Option)
The LH and RH hopper wings can be
opened separately by pressing the keys
S107 and S110.
The LH and RH hopper wings can be
closed separately by pressing the keys
S108 and S109..
Conveyor Control LH & RH, Keys
S102/S105
Overmodulating the LH & RH
Conveyors, Keys S103/S106.
Avoid having too much paving material in
the auger channel. This will relieve some
of the load on the conveyor system and
lower the head of material in the auger
channel.
The lever arms on the conveyor control
switches should be adjusted so that the
augers are submerged by 2/3 in the
paving material. (please refer to chapter
05).
When conveying material to start paving
work, especially at large paving widths,
do not over fill the auger channel because
this will exert an excess load on the
augers.
A too high head of material in the auger
channel will cause problems when you
start paving again after a short break.

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Conveyor Control ( Option )

Press the keys S101 and S104 to call up


the menu for the conveyors.
Press the keys S152 and S156: to
increase the amount of material conveyed
Press the keys S151 and S155: to reduce
the amount of material conveyed.
The amount of material in the auger
channel is controlled by the paddle type
conveyor control switches.

Avoid having too much paving material in


the auger channel. This will relieve some
of the load on the conveyor system and
lower the head of material in the auger
channel. The paddle type conveyor
control switches must be adjusted so that
the augers are submerged by 2/3 in the
paving material. When conveying material
to start paving work, especially at large
paving widths, do not over fill the auger
channel because this will exert an excess
load on the augers.
A too high head of material in the auger
channel will cause problems when you
start paving again after a short break.
Reversing the Conveyors (Option)

Press key S153 to reverse the L.H.


conveyor.
Press key S154 to reverse the R.H.
conveyor.

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Hydraulic Auger Height Adjustment


Augers Raise / Lower
Keys S129/S130 (Option)
By pressing the keys S129 and S130 the
height of the augers can be hydraulically
adapted to the mat thickness.
The height of the augers can also be
adapted by using the switch (3) located
on the main distributor (please refer to
chapter 6.4).

Raising the augers:


Press the key S129 and keep it pressed
until the required auger height has been
reached.
Lowering the augers:
Press the key S130 and keep it pressed
until the required auger height has been
reached.

By using the hydraulic auger height


adjustment, you can adapt the height of
the augers to the mat thickness being
paved.
Lower the augers to pave thinner mats.
This will reduce the head of material in
the auger channel.
Raise the augers to pave thicker mats.
This will achieve sufficient material in the
auger channel when paving at large
widths.

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Auger Control LH & RH Sides


Keys S118/S121
By pressing the keys S118 and S121, the
LH and RH augers can be independently
switched on and off.
After being switched on, the augers will
operate in the automatic mode provided
the ultrasonic sensors are connected.
The head of material in the auger channel
is controlled by ultrasonic sensors
mounted on the screed end plates.
Press the keys S117 and S122 to
manually overmodulate the augers for
filling the auger channel when the paver
is at a standstill.

Overmodulating the LH auger:


Press the key S117 and keep it pressed
until the required amount of material is in
the auger channel.
The overmodulating mode can still be
operated whether the augers are
switched on or off.
Overmodulating the RH auger:
Press the key S122 and keep it pressed
until the required amount of material is in
the auger channel.
The overmodulating mode can still be
operated whether the augers are
switched on or off.

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Auger Control when the Ultrasonic


Sensors have failed:

Remove the connecting cable for the


ultrasonic sensors.
Cancel the error message:
Press the Enter / Return key S169 to
clear the error message from the display.
Increasing or reducing the auger
speed LH side:
Press the key S118 to call up the auger
menu in the display.
To increase the auger speed, press the
key S152 and keep it pressed until the
required auger speed has been reached.
To reduce the auger speed, press the key
S151 and keep it pressed until the
required auger speed has been reached.
Increasing or reducing the auger
speed RH side:
Press the key S121 to call up the auger
menu in the display.
To increase the auger speed, press the
key S156 and keep it pressed until the
required auger speed has been reached.
Reduce the auger speed
by pressing the key S155 and keeping it
pressed until the required auger speed
has been reached.
Auger Reverse Mode LH & RH
Keys S119/S120
The augers can be reversed by pressing
the keys S119 and S120.
It is not necessary to switch off the
augers before using the reversing mode.
When operating the reverse mode, the
auger's direction of rotation on the LH or
RH side will be reversed.

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Screed Lock & Screed Load Device


Key S149

When paving materials with a low bearing


capacity, the screed lock prevents the
screed from sinking down into the mat
when the paver comes to a standstill.
The function of the screed lock is
controlled by the drive lever S24.
The screed lock will be automatically
engaged when the drive lever S24 is
returned to the neutral position.

The screed is automatically locked in its


height position when the paver's ignition
is switched off irrespective of whether the
floating mode is switched on or off.
Screed Load Device, Option for VB /
VDT-V 78 and VB / VDT-V 88 Screeds

Start-off bumps in the mat frequently


occur at low ambient temperatures (mix
temperatures). When paving thin mats
whereby the paving material has
unfavourable characteristics, a start-off
bump may occur when the machine starts
paving. This problem increases the
colder the material and the longer the
break in paving work. If you notice a startoff bump in the mat after a short break in
paving work, the bump will significantly
increase the longer the break. Measures
must be immediately taken to avoid these
start-off bumps forming in the mat.

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You can recognize a start-off bump in the


mat when the paver starts paving with
material in the auger channel. This can
be seen by the rear edge of the screed
not resting on the paved mat. There is a
gap between the rear edge of the screed
and the mat surface.
It is not always possible to avoid longer
breaks when charging the paver's hopper
with material. IR-ABG offers a screed
anti-climbing lock for the Titan pavers as
an option. This device prevents the
screed from climbing up and over any
cooled down material when the paver
starts paving again after a short break.

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Screed Load Device, Option for VB /


VDT-V 78 and VB / VDT-V 88 Screeds
The screed load device is offered as an
option to supplement the anti-climbing
lock when paving at large widths. In other
words, the screed load device extends
the function of the anti-climbing lock.
When the screed anti-climbing lock is
activated, a pre-set pressure is
simultaneously applied to the hydraulic
cylinders on the screed load device.
This prevents the screed extensions from
rising upwards.
The function of the screed load device is
controlled by the drive lever.
The pressure applied to the screed load
device mainly depends on the paving
material and paving width.
The following is a rule of thumb:
For the basic width up to 6.0 m (VDTV88) and 5,0 m (VDT-V78) - 40 %.
For paving widths up to approx. 7.5 m
- 60%.
For paving widths up to approx. 9.0 m
- 70-80%.
It is essential to check the evenness of
the paved mat after commencing paving
work and using the screed load device for
the first time.
The hydraulic pressure must be set so
that a start-off bump does not occur in the
mat.
The hydraulic pressure is limited to 100
bar which corresponds to 100 %
depending on the temperature of the
hydraulic oil.
There is a pre-load on the system of 50 %
of the set value when the paver is at a
standstill.

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Screed Load Device, Option for VB /


VDT-V 78 and VB / VDT-V 88 Screeds
Setting the maximum pressure:

Loosen the lock nut A.


The pressure is altered with the
adjusting screw B.
Screw in the adjusting screw B to
increase the pressure.
Unscrew the adjusting screw B to
reduce the pressure.
Read the pressure you have set on
the manometer C.
Tighten up the lock nut A.

Switching on the screed load device on


the main control panel:
The screed load device is switched on
(control lamp ON) and switched off (control

on
lamp OFF) with this operating key
the main control panel. If the screed load
device is activated, the screed assist will be
deactivated. If the screed assist is activated,
the screed load device will be deactivated.
Activated operating keys will appear in black
and deactivated keys will appear in grey.
Check the settings on the display every time
you start the paver.

Druck (% von Max) = Pressure in % of max.


Rampe = Ramp
Strecke (m) = Distance in metres

Settings on the main control panel:


The screed load device can be set from 0 to
100 % in steps of 5 %, whereby 100 %
corresponds to 100 bar. We do not
recommend setting the screed load device
higher than 90 %. The paving distance over
which the screed load device should be
active is set in steps of 0.5 m from 0 to 10 m.
The ramp (illustration refers) can be set from
0 to 10 m in steps of 0.5 m.
Set the parameters as follows:

56

Call up the menu with key


Call up the parameters with the arrow
buttons A.
Use +/- keys to set the required values.
Use the ON/ OFF key to select the
required function.

Titan 8820

Road Development Hameln

Screed Assist ( Option )


The pre-set pressure on the screed assist
device takes some of the weight off of the
screed.
The hydraulic pressure can be set
between 0 and 50 bar.
The paver is supplied by the factory with
the valve set at 50 bar.
Relieving the screed of some of its weight
will improve its floating behaviour when
paving materials with a low bearing
capacity.

Setting the pressure on the screed


assist:
Increasing the pressure:
Loosen the lock nut (2) on the
adjusting screw (3) located on the
pressure limiting valve (1). Access can
be gained to the valve through the RH
side door.
Screw in the adjusting screw (3).
Check the pressure with a
manometer.
The manometer is connected to the
test connection (4). Remove the
protective cap to connect the
manometer.
Tighten the lock nut (2) when the
required pressure has been reached.
Reducing the pressure:

57

Loosen the lock nut (2) on the adjusting


screw (3) located on the pressure limiting
valve (1).
Unscrew in the adjusting screw (3).
Check the pressure with a manometer.
The manometer is connected to the test
connection (4). Remove the protective
cap to connect the manometer.
Tighten the lock nut (2) when the required
pressure has been reached.

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Road Development Hameln

Screed Floating Mode, Key S124


Switching to the screed floating mode:
Press the key S125 and keep it pressed
until the screed is lowered and resting on
a sturdy base.
The green luminous diode will flash on
and off if the screed is not completely
resting on the sturdy base.
Press the key S124.
A green luminous diode will light up in the
key S124 signalling that the screed is in
the floating mode.
Switching off the screed floating mode:
Press the key S124.
The green luminous diode in the key
S124 will extinguish.
Raise the screed by pressing key S123.

After you have lowered the screed, press


the key S124 to switch to the floating
mode before you start paving work.
Screed Raise / Lower, Keys S123/S125
The key S124 for the floating mode must
be switched off before raising or lowering
the screed , i.e. the green diode must be
extinguished.
If the key S124 for the floating mode is
pressed when the screed is in the raised
position, the green luminous diode will
flash on and off as a warning.
Raising the Screed:
Press the key S123 and keep it pressed
until the screed has reached the required
position.
Lowering the Screed:
Press the key S125 and keep it pressed
until the screed has reached the required
position.

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Screed Assist, Key S127 (Option)

When the screed assist is switched on


and the screed is in the floating mode, the
transport cylinders will take some of the
weight off the screed.
When the screed assist is switched on, its
function is automatically controlled by the
drive lever S24 provided the screed is in
the floating mode.
The amount of weight taken off the
screed depends upon the pressure
adjustment made on the control valve for
the screed assist (please refer to chapter
09).
The control valve is pre-set in the factory
and, under normal circumstances, should
not be reset.

Switching on the screed assist:


Press the key S127 to switch on the
screed assist.
The green luminous diode will light up
under key S127.
Switching off the screed assist:
Press the key S127 to switch off the
screed assist.
The green luminous diode will extinguish
under key S127.

The screed assist ensures that the screed


floats on the mat when paving materials
with a low bearing capacity.

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Screed Anti-Climbing Lock, Key S126


(Option)

The screed anti-climbing lock prevents


the screed from climbing up and over the
paving material in front of the screed
which has cooled down during a longer
interruption of paving work.
The screed anti-climbing lock will only
function when the screed is in the floating
mode and the paver is moving forwards.

Switching on the screed anti-climbing


lock:
Press the key S126 to switch on the
screed anti-climbing lock.
The green luminous diode will light up
under key S126.
Switching off the screed anti-climbing
lock:
Press the key S126 to switch off the
screed anti-climbing lock.
The green luminous diode will extinguish
under key S126.

When the anti-climbing lock is switched


on, the screed is prevented from climbing
up and over the paving material for a
period of approx. 10 seconds after the
paver has started moving. Thereafter, the
screed returns to the floating mode.

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Screed Tensioning Device VB-78 / 88


(Option)

Extend the screed to its maximum paving


width.
Fit the tensioning cylinder (3) into the
swivel bracket (4).
Connect the hydraulic hoses (5) to the
tensioning cylinder.
Now extend the ram on the hydraulic
cylinder. To do this, swap the cylinder's
hoses to opposite ports on the paver (10),
i.e. the upper hose connection to the
lower port and vice versa. Thereafter
return the hose connections to their
correct ports.
Use the shackle (6) to connect the wire
rope (1) to the eye on the tensioning
cylinder (3). Bolt the connecting plate (2)
to the end plate on the Variomatic screed.
Use the shackle (7) to fasten the wire
rope (1) to the connecting plate.
The wire rope must be slack when the
Variomatic screed and the tensioning
cylinders are both fully extended.
Push the switch (9) to the ON position.
Both LH & RH cylinders will tighten the
wire rope and the screed is now
tensioned.
The screed can be extended and
retracted and the tension on the wire rope
remains constant.
To dismantle the screed tensioning device,
retract the ram on the hydraulic cylinder. To
do this, swap the cylinder's hoses to opposite
ports on the paver (10), i.e. the upper hose
connection to the lower port and vice versa.
Thereafter, return the hose connections to
their correct ports.
The remaining dismantling work is done in
the opposite sequence described above.

We recommend the application of the screed


tensioning device on Variomatic screeds at
paving widths beyond 7.0 m and on manually
extendable screeds at paving widths beyond
10.0 m. The screed tensioning device must
always be used on Variomatic screeds at
paving widths of 9.0 m.

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Tamper Control, Key S131


Menu for Tamper Control, Key S132
Keep away from moving and rotating
parts when the tampers are in operation.
Only operate the tampers with their
protective guards and covers correctly
installed. If an entry is not made within
approx. 10 seconds after pressing the
grey menu keys, the system will
automatically return to the main menu.
In the MAN mode, the tampers run
continuously whereas in the AUTO mode
they are switched on and off by the drive
lever S24. The tamper speed can be set
in the display.
Switching on the tampers:
Press the key S131 to switch on the
tampers.
The green luminous diode will light up
under key S131.
Switching off the tampers:
Press the key S131 once again to switch
off the tampers.
The green luminous diode will extinguish
under key S131.
Tampers MAN mode:
Press the key S132 (grey) to call up the
menu for the tampers in the display. By
pressing the key S150 MAN, the tampers
will run continuously in the manual mode
whatever the position of the drive lever
S24.
Tampers AUTO mode:
Press the key S132 (grey) to call up the
menu for the tampers in the display. By
pressing the key S151 AUTO, the
tampers will run in the AUTO mode and
only function when the machine is paving
with the drive lever S24 in the forward
position.

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Tamper speed min/max:


Press the key S132 (grey) to call up the
menu for the tampers in the display.
By pressing the key S153 (min), the
tampers will be immediately reduced to
the minimum speed.
By pressing the key S156 (max), the
tampers will be immediately increased to
the maximum speed.
Tamper speed -/+ :
Press the key S132 (grey) to call up the
menu for the tampers in the display.
To reduce the tamper speed, press the
key S154 (-) and keep it pressed until the
required speed has been reached.
To increase the tamper speed, press the
key S155 (+) and keep it pressed until the
required speed has been reached.

There is no general recommendation for


tamper speeds suitable for all paving
applications.
Do not run the tampers too fast as this
may lead to an over compaction and
possibly a grain destruction.
At a correct tamper speed, the screed will
lay smoothly on the paved mat and no
significant vibrations will be noticed on
the outrigger for the grade control.

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Vibration MAN mode:


Press the key S136
to call up the
vibration menu.
Press the key S150 (F1). The vibration
system is now switched to the MAN
mode. Select the required vibrator speed
using the keys S155 (F6) to S156 (F7).
Press the key S169 to clear the menu
from the display. Press the key S135
to switch on the vibration.
The green luminous diode will light up
under the key S135 .
By pressing the key S136
, the menu
for the vibration can be called up at any
time to alter the speed of the vibrators.
Vibration AUTO mode:
Press the key S136
to call up the
vibration menu.
Press the key S151 (F2).
The vibration system is now switched to
the AUTO mode.
Select the required vibrator speed using
the keys S155 (F6) to S156 (F7).
Press the key S169 to clear the menu
from the display.
Press the key S135 .
The green luminous diode will light up
under the key S135 .
The vibration is now ready for operation.
In the AUTO mode, the vibrators will only
run when the machine is paving, i.e. they
are switched on and off by the drive lever
S24.
By pressing the key S136
,the menu
for the vibration can be called up at any
time to alter the speed of the vibrators.
There is no general recommendation for
vibrator speeds suitable for all paving
applications.
Do not run the vibrators too fast because
they only serve for smoothing and closing
the mat surface and do not achieve any
significant increase in compaction.

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Screed Heating, On / Off Key S133


Screed Heating Menu, Key S134
The temperatures for the three individual
heater circuits are individually displayed and
adjusted on the main control panel.
Switching on the screed heating:
Press the key S133 to switch on the screed
heating system. The green luminous diode
will light up under key S133.
Switching off the screed heating:
Press the key S133 once again to switch off
the screed heating system.
The green luminous diode will extinguish
under key S133.
Heating Menu; Key S134:
Calling up the heating menu:
Press the key S134 (grey) and the menu for
"Heating Control" will appear in the display.
Reducing the temperature:
By pressing the keys
S150 (-) for the LH extendable screed
section,
S152 (-) for the LH half of the basic screed,
S154 (-) for the RH half of the basic screed,
S156 (-) for the RH extendable screed
section,
you can reduce the temperatures on the
individual screed sections.
Always press keys S152 and S154
simultaneously because they represent one
single heater circuit on the basic screed.
Increasing the temperature:
By pressing the keys
S151 (+) for the LH extendable screed
section,
S153 (+) for the LH half of the basic screed,
S155 (+) for the RH half of the basic screed,
S157 (+) for the RH extendable screed
section,
you can increase the temperatures on the
individual screed sections.
Always press keys S153 and S155
simultaneously because they represent one
single heater circuit on the basic screed.

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Special Functions/Help Key S174

By pressing the Help key S174 and


entering the code number 1-2-3-4, you
can gain limited access to the paver's
computer programme. A window will
appear in the display in which you can
select two functions. The third function
can only be accessed by a Service
Technician:
1.
Enter your PIN/PUK code:
(Option)
Remote data transfer per telephone
modem (mobile phone).
2.
OFFSET Adjustment:
Calibrating the starting values on the
variable displacement pumps for the
travel drive.
3.
Adjusting the Parameters:
This programme can only be accessed
and operated by a Service Technician.
Inserting the SIM card in the modem
(OPTION):

The modem is fixed on the inside of the


cover plate (1) located on the front side
off the main control.
Remove the cover plate and place the
SIM card in the insertion (2) on the
modem.
Replace and secure the cover plate.

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Entering your PIN/PUK code for


Remote Data Transfer (OPTION):

Press the Help key S174 and a window


will appear on the display requesting you
to enter your password.
Use the keys S158 to S168 and enter the
code number 1-2-3-4.
By pressing the keys S170/173 you can
move the cursor up and down in the
window.
Move the cursor to PIN/PUK and press
the Enter / Return key S169.
Now enter your PIN Code number
allocated to you by the telephone
company with your SIM telephone card.
To do this, use the keys S158 to S168.
Confirm your entry by pressing the Enter /
Return key S169.
The Remote Data Transfer system has
now been activated.
Advantages of Remote Data Transfer:
The paver's operating data can be
transferred to a distant location by
telephone modem.
An accurate remote diagnosis of errors
reduces costs.
Quicker reaction by the service engineer.

Once the PIN code has been entered it


will remain saved.
If a new SIM card is installed, the new
PIN code must also be entered and
saved.

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OFFSET Adjustment

68

If it is necessary to carry out the offset


adjustment to the travel drive pumps,
ensure the paver is at a standstill
which means that:
the drive lever S24 is in the neutral
position, the paver has reached
operating temperature and the Diesel
engine is running at approx. 1200
[1/min].
the operator must remain on the
platform during the offsetting process
in order to press the emergency
STOP button if the paver is put into
motion (caused by the offsetting
process).
all other personnel must be at a safe
distance from the paver and out of the
danger zone.
The screed must be completely raised
and safely locked in the transport
locking device.

With the offset adjustment, the starting


values on the variable displacement
pumps for the travel drive are
calibrated.
The offset adjustment is carried out if
the paver cannot be properly steered
or it does not travel in a straight line.
Always calibrate both sides one after
the other.

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Road Development Hameln

OFFSET Adjustment
OFFSET Adjustment Procedure:
Press the key S174. A text will appear
in the display requesting you to enter
your password.
Use the keys S166/S167/S168 and
S162 to enter the code number 1-2-34.
By pressing the keys S170/S173 you
can move the cursor up and down in
the window.
Move the cursor to offset adjustment
and press the Enter / Return key
S169.
The text "offset adjust RH side" will
appear in the window. Move the
cursor to the first offset adjustment
and press the Enter / Return key
S169.
Observe the calibration run through.
The offset adjustment process has
been completed if the indicator
remains still for longer than approx. 5
seconds.
Now repeat the above procedure with
the next text "offset adjust LH side".
After the procedure has been
completed for both sides, guide the
cursor to EXIT and press the Enter /
Return key S169.
(3) You can now continue to operate the
paver in the usual manner.

69

After completing the offset adjustment,


put the paver into motion in the Low
(L) paving speed stage.
Repeat the procedure if irregularities
still occur when putting the paver into
motion.

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Road Development Hameln

External Control Panels


Positioning the external control
panels:
Position the external control panels on
the insides of the LH and RH support
plates; they must not protrude outwards.
Fastening the external control panels:
Slot the three screws (6) on the LH
external control panel (5) through the
notches on the support plate and secure
them with the lock nut (7).
Connecting the external control
panels:
Ensure the paver's ignition is switched off.
Connect the cable (9) on the paver to the
socket on the control panel and secure it
by turning the bayonet catch (8) to the
right.
Storing the external control panels:
To protect the external control panels
from vandalism, safely stow them when
not in use in the storage compartment
integrated in the air intake.

Emergency STOP Key S214/S314


By pressing one of the emergency STOP
keys S214 or S314, you will stop all
paving functions, i.e. augers, conveyors,
travel drive, vibrators and tampers.
However, the Diesel engine will continue
running. The error message STOP on
external control panel will appear in the
display on the main control panel.

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Conveyor Control on the External


Control Panels
Keys S209/S210/S309/S310
The conveyor can be switched on or off
and overmodulated using the external
control panel for that particular side. After
the operating mode has been selected on
the main control panel as described in
chapter 08.01.25, a green luminous diode
will light up in the key S209 which informs
the operator that the system is ready for
operation.
Menu for Auger Control / Tow Point
Control to Opposite Sides, Keys
S207/S208/S205/S206
S307/S308/S305/S306
When paving, the head of material in front
of the screed can be controlled in a menu
function on the external control panels.
Ultrasonic sensors measure the head of
material in front of the screed which is
then shown in percent on the menu.
With this menu it is also possible to adjust
the tow point on the opposite side, i.e. the
RH tow point can be adjusted from the LH
external control panel and vice versa. If
necessary, it is also possible to uniformly
raise the screed using an external control
panel.

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Ultrasonic Sensors for Auger Control

Ultrasonic sensors (1) control the head of


paving material in the auger channel.
The paving material required is measured
contact free by the ultrasonic sensors (1).
The auger speed is automatically
controlled depending on the height of the
head of paving material selected.
Fit the ultrasonic sensors (1) to the
spigots (3) on the screed's LH and RH
end plates using the swivel clamps (2)
and then connect the cables (4) to the
electrical system.

72

Adjust the sensors so that the augers


are submerged by 2/3 in the paving
material.
Sufficient paving material must be
conveyed to the ends of the screed.
The ultrasonic sensors for EPM
pavers are not compatible with those
used on standard pavers.

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Road Development Hameln

Central Lubrication System


Interval:
Pause of 2 hours
Lubricate for 16 minutes
The central lubrication system is located
inside the pavers RH side door.

An alteration to the lubricating intervals


may be necessary when paving mineral
aggregates or cement treated materials.
Request an IR-ABG Service Technician
to perform this work.

Lubricant:
Grease Shell Darina II,
CPN: 13923115
Check the grease level in the grease
container (6) every 10 operating hours or
once a day.

73

Only operate the central lubrication


system with the safety valve (2)
installed.
It is essential to vent the air out of
the system if the central lubrication
has been operated with an empty
grease container (6).
Observe absolute cleanliness when
working on the central lubrication
system to avoid damage to the
bearings and faulty functions.
The lubricating intervals have been
pre-set by the manufacturer and
should not be altered without
contacting him.

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Road Development Hameln

Hydraulics
Hydraulics, Basic Range
Maintenance
Oil:
Shell Universal Engine Oil SAE 15W40
CPN14830921
Optional Biodegradable oil:
Shell Naturelle HF-E68
CPN: 56240237
Panolin HLP Synth 68
CPN: 14898092
The hydraulic oil must have
a purity classification of 19/17/14
according to ISO 4406:1999.
Quantity:
Approx. 130 litres
Intervals for checking the oil:
Every 10 operating hours or once a day.
Oil change intervals:
Change the oil every 1000 operating
hours or at least once a year.

Return line suction filter RKM


Type of filter:
Return line suction filter (2)
Consisting of:
Return line suction filter element
and
Repair kit
Quantity: 1
Filter change intervals:
When the EPM system displays the
illustrated warning (3).

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Changing the return line suction filter:

Open the LH inspection hatch on the


operator's platform. To do this, loosen the
screws (4) and remove the cover (5).
Loosen the four screws (6) on the lid of
the return line suction filter and then lift off
the lid (7).
Remove the filter element (8) from the
filter housing.
Insert a new filter element (8) by pushing
it into the guides in the filter housing.
Slowly fill the annular gap between the
filter element and filter housing with oil
until the filter element is filled with oil on
the inside of the element and between the
element and filter housing.
Check the seal for damage and renew it if
necessary.
Place the lid (7) back onto the filter
housing and tighten up the screws (6).
Open the breather (9) by removing the
rubber bung (10) on the lid.
Start the Diesel engine and let it run at
idling speed for approx. 5 minutes until oil
emerges.
Close the breather (9) by replacing the
rubber bung (10) in the lid.
Replace the inspection hatch (5) and
tighten up the four screws (4).
Start the Diesel engine and let it run for
approx. 5 minutes at idling speed.
Check the filter for leakages.

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Tank ventilation filter

Type of filter:
Tank ventilation filter
consisting of:
Paper filter element (13)
and
Repair kit
Quantity: 1
Filter change intervals:
Filter change every 1000 operating hours
or at least once a year.
Changing the tank ventilation filter

Open the LH inspection hatch (5) on the


operator's platform. To do this, loosen the
screws (4) and remove the cover (5).
Remove the lid (12) from the tank
ventilation filter.
Remove the filter element (13).
Place a new filter element (13) into the
housing.
Replace the lid (12) and turn it hand tight.
Replace the inspection hatch (5) and
tighten up the screws (4).
Start the Diesel engine and let it run for
approx. 5 minutes at idling speed. Check
the filter for leakages.

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Hydraulic Oil Tank


Hydraulic oil level

Checking the hydraulic oil level:


The oil level is shown on the sight glass
(1) located on the hydraulic oil tank.
The maximum oil level must not exceed
2/3 of the sight glass.
Oil must be added if it has reached the
minimum oil level.
Topping up with hydraulic oil:
Open the filler neck (with tank ventilation
filter) (2) on the hydraulic oil tank.
Top up with hydraulic oil through the filler
neck (2) with a quality of oil according to
the specifications of Ingersoll-Rand ABG.
Check the oil level in the sight glass (1).
If the oil level is correct, replace the lid on
the filler neck (2).

The hydraulic oil must have


a purity classification of 19/17/14
according to ISO 4406:1999.

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Changing the hydraulic oil:


Emptying the tank:
Open the LH side door.
Loosen the clamp (3), remove the drain
hose (4) and remove the protective cap
(5) from the end of the hose.
The end of the hose (4) must discharge
into a suitable container large enough to
take up approx. 200 litres of oil.
After the tank (6) has been completely
drained, place the protective cap (5) back
onto the drain hose (4). Now fasten the
drain hose back into the clamp (3).
Unscrew the magnet (7) and remove any
metal chips collected from the system.
Replace the magnet in the hydraulic oil
tank.
Filling the tank:
Open the LH inspection (9) hatch on the
operator's platform. To do this, loosen the
screws (10) and remove the cover.
Unscrew the threaded filler connection (8)
for filling up the entire quantity of oil.
Fill hydraulic oil into the tank through the
filler connection (8) with a quality
according to the specifications of
Ingersoll-Rand ABG.
Close the filler connection (8) when the
correct hydraulic oil level has been
reached.

The hydraulic oil must have a purity


classification of 19/17/14 according to
ISO 4406:1999.

78

Titan 8820

Road Development Hameln

Transport Control Panel

The crawler tracks are automatically


tensioned when the Diesel engine is
started.

Turn the ignition switch S1 to Pos. 1 for


approx. 30 seconds until the EPM system
shows EMERGENCY on the external
control panel.
Turn the ignition switch S1 to start the
Diesel engine and release it as soon as
the engine has started.
Speed stage selector switch on the
Transport Control Panel
Toggle switch S441
Transport speed stage:
Push the toggle switch S441 to the H
position.
Paving speed stage:
Push the toggle switch S441 to the L
position.

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Road Development Hameln

Operating the Paver if the I/O Module


for the Travel Drive is Faulty
Changing the I/O Module 1 for the travel
drive in the main distributor:
Release both door fasteners (4).
Swing open the door on the main
distributor.
Remove the electrical connections
from the I/O Module 1 for the travel
drive and loosen the fastening screw.
Remove the I/O Module 1 for the
travel drive from the main distributor
(4).
Place the I/O Module 7 taken from the
Thermo Control or a new I/O module
in the main distributor for the travel
drive, Module 1 and tighten the
fastening screw and replace the
electrical connections.
Close the door on the main distributor
(4) and lock the door fasteners..

The I/O Modules 1 to 4 have the same


design and are interchangeable.
Due to its design, the I/O Module 7 for the
Thermo Control can be used as a
replacement for any of the I/O Modules 1
to 4.
Ensure that the I/O Modules 1 to 4 are
not used to replace the I/O Module 7 for
the Thermo Control because they have a
different design.
If the fault cannot be rectified, contact
your nearest INGERSOLL-RAND ABG
Service Partner..

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Road Development Hameln

Operating the Paver if the I/O Module


for the Travel Drive is Faulty
Switch off the Diesel engine and the
ignition before exchanging the I/O module
for the travel drive (Module 1) in the main
distributor with the I/O module for the
Thermo Control (Module 7) in the switch
cabinet..
Switch off the paver's current supply with
the battery master switch (1).

If the I/O module for the travel drive


(Module 1) develops a fault, you can
still operate the paver almost in the
usual manner.
All you have to do is exchange the
faulty I/O module for the travel drive
(Module 1) with the module for the
Thermo Control (Module 7).
The screed heating system must then
be switched from the automatic to the
manual operating mode (please refer
to chapter 07.10.02).

Operating the Paver if the I/O Module


for the Travel Drive is Faulty
Changing the I/O Module 7 for the
Thermo Control in the switch cabinet:
If you do not have a serviceable I/O
module for the Thermo Control at hand, it
will be necessary to switch the screed
heating system from automatic to the
manual operating mode in the switch
cabinet (please refer to chapter
07.10.02).
Fit a new I/O module to the Thermo
Control (Module 7) as soon as possible.

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Towing the paver when the Diesel


engine is not running
Connect the tow bar between the towing
vehicle and the paver.
1. Manually releasing the parking brake
All tools required are contained in the tool
kit.
(1) = LH brake
(2) = T-piece
(3) = RH brake
(4) = Valve unit
(5) = Grease gun
(6) = Pressure line
(7) = Return line
(8) = Brake valve
Use the valve unit (4) and the grease gun
(5) contained in the tool kit.
Unscrew the sealing cap from the valve
unit (4).
Unscrew the T-piece (2) from the brake
valve (8).
Close the brake valve (8) by screwing on
the sealing cap from the valve unit (4).
Screw the valve unit (4) onto the T-piece
(2).
Connect the grease gun (5) to the valve
unit (4).
Apply grease to the brake with approx. 25
to 30 pumps on the grease gun (5).
If the LH brake (1) and the RH brake (3)
do not release, use one further pump on
the grease gun.
Exceeding the number of pumps on the
grease gun will lead to damage in the
transmission gear.
The LH (1) and RH (3) spring loaded
brakes have now been released.
The paver can now be towed.

82

Location of the brake valve (8):


Underneath the operator's platform
between the Diesel engine and the
generator.

Titan 8820

Road Development Hameln

Towing the Paver


Releasing the hydraulic pumps to permit
a free flow of oil:
The oil can flow freely by screwing in the
adjusting screws (1) until they are flush
with the lock nuts on both tandem
mounted drive pumps.

Loosen the lock nuts on both adjusting


screws (1).
Screw in the adjusting screws (1) until
they are flush with the lock nuts.
Retighten the lock nuts.

The maximum towing speed must not


exceed 1 km/h.
Only tow the paver out of the danger
zone.
Connect a tow bar between the paver and
the towing vehicle.

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Jump starting the Diesel engine


Disconnect the following components
from the paver's electrical system:
Main control panel
External Control Panels
Levelling system
All other electrical components (options).
Procedure for jump starting:
Connect one end of the jumper cable
to the lower terminal (10) on the
battery master switch (1) located next
to the batteries (9).
Now connect the other end of that
cable to the positive terminal (+) on
the external battery.
Then connect one end of the second
jumper cable to the negative (-)
terminal on the external battery.
Finally, connect the other end of the
second jumper cable to a bear metal
part on the paver.
You can now start the Diesel engine
with the ignition switch.
Procedure after jump starting:
Remove the jumper cables in the
opposite sequence described above.
Do not reconnect any electrical
components previously disconnected.
Use the transport control panel to
move the paver out of any possible
danger zone.
Switch off the Diesel engine and
rectify the fault which made it
necessary to jump start the paver.
After the fault has been rectified, start
the Diesel engine once again.

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Emergency Control
Emergency Control using the
External Control Panels

All operating keys and control elements


must be free and easily accessible. Never
operate more than one key or control
element at the same time which actuates
a contrary function on the paver.

All functions described in this chapter will


only operate in the emergency control
mode.
The active element will be shown in
brackets on the display.
The emergency control mode will only
function when the main control panel is
not connected to the paver.
Paving in the emergency control mode
can only be done with the transport
control panel and the external control
panels.

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Starting the Diesel Engine Using


the Transport Control Panel
Ignition Switch S1

Fully acquaint yourself with all its


functions before starting the paver.
Ensure there are no persons or objects in
the danger zone. Switch all functions to
the neutral position before starting the
Diesel engine. Do not actuate the ignition
switch for more than 20 seconds without
a break, otherwise the starter motor will
be damaged by overheating.
After starting the Diesel engine with the
ignition switch S1, the system will require
about 40 seconds for the engine speed to
reach 1400 rpm. Thereafter, the functions
can be operated on the transport control
panel. The engine speed is governed by
the paver's system and cannot be altered
on the transport control panel. Only move
the paver after the engine speed has
reached 1400 rpm.

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Road Development Hameln

Menu for the Diesel Engine in


Emergency Control
Keys S205/S206/S207/S208
Starting the Diesel Engine
Keep pressing the key S205 until the
menu for the Diesel engine appears in the
display. Keep pressing the OK key S206
until the text Diesel Engine Start/[Stop]
appears in the display. Press the key
S207, the word [Start] will appear in
brackets and the Diesel engine will be
started.
Stopping the Diesel Engine
Keep pressing the key S205 until the
menu for the Diesel engine appears in the
display.
Keep pressing the OK key S206 until the
text Diesel Engine [START] / [STOP]
appears in the display. Press the key
S208, the word [Stop] will appear in
brackets and the Diesel engine will stop.

Menu for Increasing / Reducing the


Engine Speed +/-:
Keep pressing the key S205 until the
menu for the Diesel engine appears in the
display. Keep pressing the OK key S206
until the text Engine Speed +/[-] appears
in the display. To reduce the engine
speed, press the key S208 and the
symbol [-] will appear in brackets and
then keep pressing key S208 until the
required engine speed is reached. To
increase the engine speed, press the key
S207 and the symbol [+] will appear in
brackets and then keep pressing key
S207 until the required engine speed in
reached.

87

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Road Development Hameln

Hopper Wings Open / Close


Toggle Switch S410
Transport Control Panel
The hopper wings are opened and closed
using the toggle switch S410.

Opening the hopper wings:


Press the toggle switch S410 to the rear
OPENING position and keep it pressed
until both hopper wings have opened.
Closing the hopper wings:
Press the toggle switch S410 to the front
CLOSING position and keep it pressed
until both hopper wings have closed.

Screed Raise / Lower


Toggle Switch S423
Transport Control Panel

Raising the screed:


Press the toggle switch S423 forwards in
the direction of the arrow RAISE to raise
the screed to the required position.
Lowering the screed:
Press the toggle switch S423 to the rear
in the direction of the arrow LOWER to
lower the screed to the required position.

88

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Road Development Hameln

Steering the Paver with the


Transport Control Panel
Steering Potentiometer R417

Never move the paver if the steering


system does not react to turns on the
steering potentiometer. The front and rear
of the paver will swing out when cornering
or steering around curves. Ensure there
is sufficient safety distance between the
paver, persons, buildings and other
objects.
Steering the paver

By turning the steering potentiometer


R417 to the left or to the right, you will
alter the paver's direction of travel.

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Drive Lever S424 on the


Transport Control Panel

Neutral position:
The drive lever S24 is locked in the
centre neutral position.
Forward travel position :
Gently push the drive lever S424
forwards as far as the limit stop.
Reverse travel position :
Gently pull the drive lever S424
backwards as far as the limit stop..

Speed Potentiometer R415 on the


Transport Control Panel

Increasing the speed:


Slowly turn the speed potentiometer
R415 clockwise until the required speed
has been reached.
Reducing the speed:
Slowly turn the speed potentiometer
R415 anti-clockwise until the required
speed has been reached or the paver has
come to a standstill.

90

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Road Development Hameln

Menu for the Screed Floating


Mode in Emergency Control
Keys S205/S206/S207/S208
Switching to the screed floating mode:
Keep pressing the key S205 until the
menu for the floating mode appears in the
display.
Keep pressing the OK key S206 until the
text Floating Mode ON/[OFF] appears in
the display.
Press the key S207, the word [ON] will
appear in brackets and the floating mode
is switched on.
Switching off the screed floating
mode:
Keep pressing the key S205 until the
menu for the floating mode appears in the
display.
Keep pressing the OK key S206 until the
text Floating Mode [ON]/OFF appears in
the display.
Press the key S208, the word [OFF] will
appear in brackets and the floating mode
is switched off.

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Road Development Hameln

Menu for the Levelling System in


Emergency Control
Keys S205/S206/S207/S208
Switching on the levelling system:
Keep pressing the key S205 until the
menu for the levelling system appears in
the display.
Keep pressing the OK key S206 until the
text Levelling System ON/[OFF] appears
in the display.
Press the key S207, the word [ON] will
appear in brackets and the levelling
system is switched on.
Switching off the levelling system:
Keep pressing the key S205 until the
menu for the levelling system appears in
the display.
Keep pressing the OK key S206 until the
text Levelling System [ON]/OFF appears
in the display. Press the key S208, the
word [OFF] will appear in brackets and
the levelling system is switched off.
Switching the levelling system to the
manual mode:
Keep pressing the key S205 until the
menu for the levelling system appears in
the display.
Keep pressing the OK key S206 until the
text Levelling System auto/[man] appears
in the display. Press the key S208, the
word [man] will appear in brackets and
the levelling system will function whatever
the position of the drive lever S424.
Switching the levelling system to the
automatic mode:
Keep pressing the key S205 until the
menu for the levelling system appears in
the display.
Keep pressing the OK key S206 until the
text Levelling System auto/[man] appears
in the display. Press the key S207, the
word [auto] will appear in brackets and
the levelling system will be switched on
and off by the drive lever S424.

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Road Development Hameln

Tampers in Emergency Control


Keys S205/S206/S207/S208
Switching the tampers to the manual
control mode:
Keep pressing the key S205 until the menu
for the tampers appears in the display.
Keep pressing the OK key S206 until the text
Tampers [auto]/man appears in the display.
Switch the tampers to the manual mode by
pressing key S208, the word [man] will
appear in brackets and the tampers will run
whatever the position of the drive lever S424.
Switching the tampers to the automatic
control mode:
Keep pressing the key S205 until the menu
for the tampers appears in the display.
Keep pressing the OK key S206 until the text
Tampers auto/[man] appears in the display.
Switch the tampers to the automatic mode by
pressing the key S207, the word [auto] will
appear in brackets and the tampers will be
switched on and off by the drive lever S424.
Increasing / reducing the tamper speed +/Keep pressing the key S205 until the menu
for the tampers appears in the display.
Keep pressing the OK key S206 until the text
Tamper Speed [+]/[-] appears in the display.
Reduce the tamper speed by pressing key
S208, [-] will appear in brackets and then
continue to press key S208 until the required
speed has been reached.

Increase the tamper speed by pressing


key S207, [+] will appear in brackets and
then continue to press key S207 until the
required speed has been reached.
Switching on the tampers:
Keep pressing the key S205 until the menu
for the tampers appears in the display.
Keep pressing the OK key S206 until the text
Tampers ON/[OFF] appears in the display.
Switch on the tampers by pressing the key
S207 and the word [ON] will appear in
brackets.
Switching off the tampers:
Keep pressing the key S205 until the menu
for the tampers appears in the display.
Keep pressing the OK key S206 until the text
Tampers [ON] / OFF appears in the display.
Switch off the tampers by pressing the key
S208 and the word [OFF] will appear in
brackets.

93

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Road Development Hameln

Vibration Control in Emergency


Control, Keys S205/S206/S207S208
S305/S306/S307/S308
Switching on the vibration system:
Keep pressing the key S205 until the
menu for the vibration system appears in
the display.
Keep pressing the OK key S206 until the
text Vibration ON / [OFF] appears in the
display.
To switch on the vibration, press the key
S207 and the word [ON] will appear in
brackets.
Switching off the vibration:
Keep pressing the key S205 until the
menu for the vibration system appears in
the display .
Keep pressing the OK key S206 until the
text Vibration [ON ] / OFF appears in the
display.
To switch off the vibration, press key
S208 and the word [OFF] will appear in
brackets.
Switching the vibration to the MAN
mode:
Keep pressing the key S205 until the
menu for the vibration system appears in
the display.
Keep pressing the OK key S206 until the
text Vibration AUTO / [MAN] appears in
the display.
To switch on the vibration, press the key
S207 and [MAN] will appear in brackets
and the vibration will run whatever the
position of the drive lever S424.
Switching the vibration to the AUTO
mode:
Keep pressing the key S205 until the
menu for the vibration system appears in
the display .
Keep pressing the OK key S206 until the
text Vibration AUTO / [MAN] appears in
the display.
Switch to the AUTO mode by pressing
key S207, the word [AUTO] will appear in
brackets and the vibration will be
switched on and off by the drive lever
S424.
94

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Road Development Hameln

Menu for the Screed Heating using the


LH & RH External Control Panels in
Emergency Control,
Keys S205/S305
Switching on the screed heating:
Keep pressing the key S205 until the
menu for the screed heating appears in
the display (1).
Keep pressing the OK key S206 until the
text Heating ON / [OFF] appears in the
display.
To switch on the heating, press the key
S207 and [ON] will appear in brackets.
Reducing the temperature:
By repeatedly pressing the key S206, you
can call up the individual screed sections
in the display. For example, keep
pressing the key S206 until the words
Heating L appears. The temperature can
now be reduced on the LH extendable
screed section. Then keep pressing the
key S208 (-) until the required
temperature has been reached. Repeat
this procedure to reduce the temperature
on the remaining screed sections.
Increasing the temperature:
By repeatedly pressing the key S206, you
can call up the individual screed sections
in the display. For example, keep
pressing the key S206 until the words
Heating L appears. The temperature can
now be increased on the LH extendable
screed section. Then keep pressing the
key S207 (+) until the required
temperature has been reached. Repeat
this procedure to increase the
temperature on the remaining screed
sections.
Switching off the screed heating:
Keep pressing the key S205 until the
menu for the screed heating appears in
the display.
Keep pressing the OK key S206 until the
text Heating [ON] / OFF appears in the
display.
To switch off the heating, press the key
S208 and [OFF] will appear in brackets.

95

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Road Development Hameln

Allocation of Functions to the I/O Modules


Module No. 1
Module Functions

I/O
I-IN O
I-IN I
I-NI 2
I-IN 3
U.IN 0
U-IN 1
U-IN 2
U-IN 3
DIN O- GND (f)
DIN 1- GND (f)
DIN 2 UB (f)
DIN 3 UB (f)
DIN 4 - GND
DIN 5 GND
DIN 6 UB
DIN 7 UB
OUT 0 (PWM)
OUT 2 (PWM)
OUT 2 (PWM)
OUT 3 (PWM)
OUT 4 (PWM)
OUT 5 (PWM)
OUT 6 (PWM)
OUT 7 (PWM)
OUT 8
OUT 9
OUT 10
OUT 11

96

Travel Drive
Screed
Hydraulics
Warning Horn

I/O Function
Signal Exhaust Filter
Drive Lever Forwards (Emergency Control)
Drive Lever Reverse (Emergency Control)
Steering Potentiometer (Emergency Control)
Speed Potentiometer (Emergency Control)

Filter Pressure Sensor 1


Filter Pressure Sensor 2
LH Rotary Sensor
RH Rotary Sensor
High / Low Speed stage (Emergency Control)
Signal Crown Control Raise
Signal Crown Control Lower
Drive Pump LH Forwards
Drive Pump RH Reverse
Drive Pump LH Reverse
Drive Pump RH Reverse
Drive Motor LH (High / Low)
Drive Motor RH
Crown Control Raise
Crown Control Lower
Brake
Control Cable Paving Signal
Control Cable Reverse Travel
Warning Horn

Titan 8820

Plug
XE 3
XE 4
XE 5
XE 6
XE 7
XE 8
XE 9
XE 10
XE 11
XE 12
XE 13
XE 14
XE 15
XE 16
XE 17
XE 18
XA 3
XA 4
XA 5
XA 6
XA 7
XA 8
XA 9
XA 10
XA 11
XA 12
XA 13

Connection

S31
S32
B3
B4

Y 1.2
Y 2.1
Y 1.1
Y 2.2
Y 3 (Y 3 Y4)
Y4
Y 94.2
Y 94.1
Y 10

Road Development Hameln

Module No. 2
Module Functions

I/O
I-IN 0
I-IN 1
I-IN 2
I-IN 3
U-IN 0
U-IN 1
U-IN 2
U-IN 3
DIN 0 GND (f)
DIN 1 GND (f)
DIN 2 UB (f)
DIN 3 UB (f)
DIN 4 GND
DIN 5 GND
DIN 6 UB
DIN 7 UB
OUT 0 (PWM)
OUT 1 (PWM)
OUT 2 (PWM)
OUT 3 (PWM)
OUT 4 (PWM
OUT 5 (PWM)
OUT 6 (PWM)
OUT 7 (PWM)
OUT 8
OUT 9
OUT 10
OUT 11

97

Levelling System (incl. CAN)


Hopper
Engine
Central Lubrication System
Screed
I/O Function
Hopper Open (Emergency Control)
Hopper Close (Emergency Control)
Switch Air Filter
Switch Fuel Filter
D+
Hydr. Temperature Sensor B 31
Fuel Level
Signal Tow Point LH Raise
Signal Tow Point LH Lower
Empty Grease Container, Central Lub. System
Plunger Detector, Central Lubrication System
Signal Tow Point RH Raise
Signal Tow Point RH Lower
Signal Heating
Fumes Extraction
Oil Cooler Fan
Starter Motor
Central Lubrication System
Tow Point LH Raise (Levelling System)
Tow Point LH Lower (Levelling System)
Tow Point RH Raise (Levelling System)
Tow Point RH Lower (Levelling System)
Hopper Open
Hopper Close
Hopper Wing LH Lock
Hopper Wing RH Lock

Titan 8820

Plug
XE 3
XE 4
XE 5
XE 6
XE 7
XE 8
XE 9
XE 10
XE 11
XE 12
XE 13
XE 14
XE 15
XE 16
XE 17
XE 18
XA 3
XA 4
XA 5
XA 6
XA 7
XA 8
XA 9
XA 10
XA 11
XA 12
XA 13
XA 14

Connection

B 31

Y 13.2
Y 13.1
Y 14.2
Y 14.1
Y 20.1
Y 20.2
Y 25
Y 26

Road Development Hameln

Module No. 3
Module Functions

I/O
I-IN 0
I-IN 1
I-IN 2
I-IN 3
U-IN 0
U-IN 1
U-IN 2
U-IN 3
DIN 0 GND (f)
DIN 1 GND (f)
DIN 2 UB (f)
DIN 3 UB (f)
DIN 4 GND
DIN 5 GND
DIN 6 UB
DIN 7 UB
OUT 0 (PWM)
OUT 1 (PWM)
OUT 2 (PWM)
OUT 3 (PWM)
OUT 4 (PWM)
OUT 5 (PWM)
OUT 6 (PWM)
OUT 7 (PWM)
OUT 8
OUT 9
OUT 10
OUT 11

98

Conveyors
Augers
Tampers & Vibration

I/O Function
Material Temperature (PT100)
Reference Voltage, Mix Temperature

US Sensor LH Auger
US Sensor RH Auger
Conveyor Sensor LH
Conveyor Sensor RH

Rotary Sensor Tampers


Handset Augers Raise
Handset Augers Lower
Signal Paving Speed
Auger LH
Auger LH Reverse
Auger RH
Auger RH Reverse
Conveyor LH
Conveyor RH
Tampers
Vibration
Augers Raise
Augers Lower
Conveyor LH Reverse
Conveyor RH Reverse

Titan 8820

Plug
XE 3
XE 4
XE 5
XE 6
XE 7
XE 8
XE 9
XE 10
XE 11
XE 12
XE 13
XE 14
XE 15
XE 16
XE 17
XE 18
XA 3
XA 4
XA 5
XA 6
XA 7
XA 8
XA 9
XA 10
XA 11
XA 12
XA 13
XA 14

Connection

Y 5.2
Y 5.1
Y 6.2
Y 6.1
Y 7.2
Y 8.2
Y 23
Y 11
Y 31.2
Y 31.1
Y 7.1
Y 8.1

Road Development Hameln

Module No. 4
Module Functions

I/O
I-IN 0
I-IN 1
I-IN 2
I-IN 3
U-IN 0
U-IN 1
U-IN 2
U-IN 3
DIN 0 - GND (f)
DIN 1 GND (f)
DIN 2 UB (f)
DIN 3 UB (f)
DIN 4 GND
DIN 5 GND
DIN 6 UB
DIN 7 UB
OUT 0 (PWM)
OUT 1 (PWM)
OUT 2 (PWM)
OUT 3 (PWM)
OUT 4 (PWM)
OUT 5 (PWM)
OUT 6 (PWM)
OUT 7 (PWM)
OUT 8
OUT 9
OUT 10
OUT 11

99

Screed Lock
Screed Assist
Screed Floating Mode
Variomatic
Screed Raise / Lower
I/O Function
Switch / Sensor Screed Floating Mode
Signal Paving Speed
210 bar Signal
Switch S8 Tensioning Cylinders

Screed Raise (Emergency Control)


Screed Lower (Emergency Control)
Flasher Lamp
Screed Anti-Climbing Lock LH & RH
Screed Floating Mode
Screed Load Device
Screed Assist
210 bar Valve
Screed Raise
Screed Lower
Screed LH Retract
Screed LH Extend
Screed RH Retract
Screed RH Extend

Titan 8820

Plug
XE 3
XE 4
XE 5
XE 6
XE 7
XE 8
XE 9
XE 10
XE 11
XE 12
XE 13
XE 14
XE 15
XE 16
XE 17
XE 18
XA 3
XA 4
XA 5
XA 6
XA 7
XA 8
XA 9
XA 10
XA 11
XA 12
XA 13
XA 14

Connection

Y 15 - Y 16
Y 18 Y 17
Y 30
Y 19
Y 24.2
Y 29.2
Y 29.1
Y 21.2
Y 21.1
Y 22.2
Y 22.1

Road Development Hameln

Module No. 7
Module Functions
I/O
I-IN 0
I-IN 1
I-IN 2
I-IN 3
U-IN 0
U-IN 1
U-IN 2
U-IN 3
DIN 0 GND (f)
DIN 1 GND (f)
DIN 2 UB (f)
DIN 3 UB (f)
DIN 4 GND
DIN 5 GND
DIN 6 UB
DIN 7 UB
OUT 0 (PWM)
OUT 1 (PWM)
OUT 2 (PWM)
OUT 3 (PWM)
OUT 4 (PWM)
OUT 5 (PWM)
OUT 6 (PWM)
OUT 7 (PWM)
OUT 8
OUT 9
OUT 10
OUT 11

100

Thermo Control
Electric Heating
I/O Function
Temperature Sensor 1
Temperature Sensor 2
Temperature Sensor 3
Temperature Calibration

Earth Signal
D+

Contact Control 1
Contact Control 2
Contact Control 3

Titan 8820

Plug
XE 3
XE 4
XE 5
XE 6
XE 7
XE 8
XE 9
XE 10
XE 11
XE 12
XE 13
XE 14
XE 15
XE 16
XE 17
XE 18
XA 3
XA 4
XA 5
XA 6
XA 7
XA 8
XA 9
XA 10
XA 11
XA 12
XA 13
XA 14

Connection

Road Development Hameln

Vario Screed Extension for VDT and MB Screeds

With the Vario screed extension, it is possible to use manually adjustable screeds on
paving jobs with a tapering in the cross section. This reduction in the paving width
can be caused by drain channels or bridge abutments etc. Without the possibility of
slightly reducing the paving width, the screed must be manually reduced or raised
until the obstruction has been overtaken a time consuming operation -.
The new Vario screed extensions permit the paving width to be hydraulically reduced
by 0.75 m on each side. The contractor gains a higher degree of flexibility on paving
jobs with width reductions and can significantly increase his efficiency.
Additional Remarks

101

As it is not possible to use the screed without the Vario extension, the basic
width of a 2.5 m manual screed will be 4.5 m and the basic width of a 3.0 m
manual screed will be 5.0 m.

Titan 8820

Road Development Hameln

102

Titan 8820

Road Development Hameln

Additional Working Lights( Option )


Additional working lights (1) are available
as an option. They are mounted on either
side of the paver just below the roof
supports and light up the auger channel
during poor light conditions or during
night paving work.

Xenon Floodlights ( Option )


Xenon floodlights (2) are available as an
option for improving visibility during night
paving work.

103

Titan 8820