Abg 225 325 PDF

Ref. No.
VOE21A1004217 English
CPN 80846710
Printed in Sweden 2008-05 CST
Volvo, Hameln
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
California
Proposition 65 Warning
Battery posts, terminals and other related accessories
contain lead and lead compounds, chemicals known
to the State of California to cause cancer and other
reproductive harm.
Wash hands after handling.
Table of Contents
INTRODUCTION
PROCEDURE WHEN RECEIVING THE MACHINE ..................................................................... 0-3

DATA REQUIRED FOR ORDERING SPARE PARTS................................................................... 0-3
MACHINE IDENTIFICATION PLATE ....................................................................................... 0-3
ENGINE IDENTIFICATION PLATE .......................................................................................... 0-4
SAFEKEEPING THE OPERATING MANUAL AND FIRST AID BOX ............................................. 0-4
SAFETY
EXPLANATION OF THE SAFETY SYMBOLS ........................................................................... 1-2

IMPORTANT GENERAL INFORMATION .................................................................................. 1-3
INTENDED AND UNINTENDED USE ...................................................................................... 1-4
INTENDED USE ........................................................................................................... 1-4
UNINTENDED USE....................................................................................................... 1-4
RESPONSIBILITIES OF THE USER / CONTRACTOR ................................................................. 1-5
RESPONSIBILITIES OF THE PERSONNEL .............................................................................. 1-7
INSTRUCTIONS FOR SPECIAL HAZARDS .............................................................................. 1-8
PRECAUTIONS FOR HANDLING HAZARDOUS GOODS ..................................................... 1-8
PRECAUTIONS WHEN HANDLING GAS HEATING SYSTEMS ........................................... 1-10
GAS HOSE ROUTING ......................................................................................... 1-12
SAFETY PRECAUTIONS WHEN GAS ESCAPES .............................................................. 1-13
SAFETY PRECAUTIONS WHEN THE MACHINE TOUCHES LIVE ELECTRIC CABLES ............. 1-14
INSTRUMENTS AND CONTROLS
MACHINE OVERVIEW ......................................................................................................... 2-3

OPERATOR'S PLATFORM ................................................................................................... 2-4
OPERATOR'S SEAT............................................................................................................ 2-5
STANDARD SEAT ........................................................................................................ 2-5
DELUXE SEAT ............................................................................................................ 2-6
CONTROL PANEL .............................................................................................................. 2-7
EXTERNAL CONTROL PANELS .......................................................................................... 2-20
STORAGE COMPARTMENTS ............................................................................................. 2-22
FUEL TANK ..................................................................................................................... 2-23
CENTRAL LUBRICATION SYSTEM (OPTION)....................................................................... 2-24
MAT THICKNESS SCALES ................................................................................................. 2-25
EMULSION SPRAYING SYSTEM (OPTION).......................................................................... 2-26
POTENTIOMETERS FOR VIBRATORS AND TAMPERS ........................................................... 2-27
SWITCH OFF THE LEVELLING CYLINDERS IN CASE OF BREAKDOWNS ................................. 2-28
SCREED HEATING SYSTEM (OPTION)............................................................................... 2-30
ELECTRONIC LEVELLING SYSTEM (OPTION) ..................................................................... 2-32
ELECTRICS ..................................................................................................................... 2-33
BATTERY MASTER SWITCH ....................................................................................... 2-33
WORKING LIGHTS ..................................................................................................... 2-34
SOCKETS / FUSES ON THE PAVER'S LH REAR WALL.................................................. 2-35
SOCKETS ON THE PAVER'S RH REAR WALL .............................................................. 2-36
SOCKETS ON THE LH AND RH EXTERNAL CONTROL PANELS ..................................... 2-37
SWITCH CABINET ON THE OPERATOR'S PLATFORM .................................................... 2-38
SWITCH CABINET ON THE PAVER'S REAR WALL......................................................... 2-39
SOCKETS ON THE PAVER'S REAR WALL .................................................................... 2-40
Track Paver Titan 225/325 Ref. No. VOE21A1004217 1

Table of Contents
OPERATION
IMPORTANT INSTRUCTIONS FOR OPERATION .......................................................................3-3

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

Table of Contents
ADJUSTING THE CONVEYOR CONTROL (PADDLE TYPE CONTROL SWITCHES) ............... 3-50
TOO MUCH MATERIAL IN THE AUGER CHANNEL .................................................... 3-50
NOT ENOUGH MATERIAL IN THE AUGER CHANNEL ................................................ 3-50
DIRECTION INDICATOR, SETTING UP .......................................................................... 3-51
ELECTRONIC LEVELLING SYSTEM .............................................................................. 3-51
PAVING .......................................................................................................................... 3-52
SETTING THE OPERATING MODE AUTOMATIC ............................................................ 3-52
MAT THICKNESS, ADJUSTING .................................................................................... 3-53
SCREED FLOATING MODE ......................................................................................... 3-54
SCREED HEATING, ON / OFF ................................................................................... 3-56
PAVING IN THE AUTOMATIC MODE ............................................................................. 3-57
PAVING MATERIAL PRONE TO SEGREGATION ....................................................... 3-58
MAT THICKNESS IS NOT CORRECT ...................................................................... 3-58
TOW POINT SINKS DOWN DURING PAVING WORK ................................................. 3-59
CONVEYING THE PAVING MIX TO ONE SIDE .......................................................... 3-59
PAVING MATERIAL NOT CONVEYED FAST ENOUGH ............................................... 3-60
SETTING THE PRESSURE ON THE SCREED ASSIST ............................................... 3-60
DAILY PROCEDURE AT THE END OF PAVING WORK ............................................................ 3-61
LOADING AND TRANSPORT .............................................................................................. 3-62
LOADING BY CRANE.................................................................................................. 3-62
LOADING ON A VEHICLE WITH RAMPS ........................................................................ 3-65
LASHING THE MACHINE ON THE VEHICLE ................................................................... 3-66
MAINTENANCE
IMPORTANT INSTRUCTIONS ................................................................................................ 4-2

BEFORE STARTING MAINTENANCE WORK .................................................................... 4-5
HANDLING HAZARDOUS MATERIALS ............................................................................ 4-6
WELDING WORK ON THE PAVER ................................................................................. 4-6
FIRST OIL CHANGE..................................................................................................... 4-6
MAINTENANCE CHART ....................................................................................................... 4-7
MAINTENANCE WORK ...................................................................................................... 4-10
MACHINE (GENERAL) ................................................................................................ 4-10
CLEANING THE MACHINE ................................................................................... 4-10
TIGHTEN THREADED CONNECTIONS .................................................................... 4-10
DIESEL ENGINE ........................................................................................................ 4-11
CHECK THE ENGINE OIL LEVEL ........................................................................... 4-11
FUEL FILTER - DRAINING OFF THE WATER ........................................................... 4-12
ELECTRICAL SYSTEM ................................................................................................ 4-13
CHARGE THE BATTERY ...................................................................................... 4-14
GREASING THE BATTERY TERMINALS .................................................................. 4-14
HYDROSTATIC SYSTEM ............................................................................................. 4-15
HIGH PRESSURE FILTER FOR THE LEVELLING CYLINDERS AND AUGERS .............. 4-16
FEED PRESSURE FILTER FOR THE TRAVEL DRIVE AND TAMPER DRIVE
(ONLY FOR VDT AND VDT-V SCREEDS) ........................................................... 4-17
CLEANING THE VENT FILTER .............................................................................. 4-18
CLEANING THE HYDRAULIC OIL COOLER AND RADIATOR ..................................... 4-19
TRANSMISSION GEARS ............................................................................................. 4-20
CHECK THE PUMP DISTRIBUTOR GEAR ................................................................ 4-20
CHECK THE TRAVEL DRIVE TRANSMISSIONS ........................................................ 4-20
Track Paver Titan 225/325 3

Table of Contents
DRIVE CHAINS AND V-BELTS ......................................................................................4-21

V-BELTS ............................................................................................................4-22
DRIVE CHAINS ....................................................................................................4-23
TENSIONING THE CONVEYORS ............................................................................4-24
AUGER CENTRE DRIVE.......................................................................................4-25
AUGER OUTER DRIVES ......................................................................................4-26
PRESERVATION FOR LONGER PERIODS OF STANDSTILL .....................................................4-27
LUBRICATION PLAN ..........................................................................................................4-28
GREASE POINTS .......................................................................................................4-29
CENTRAL LUBRICATION SYSTEM (OPTION) .................................................................4-32
OIL CHANGE, TRANSMISSION GEARS .........................................................................4-33
OIL CHANGE, PUMP DISTRIBUTOR GEAR....................................................................4-34
OIL CHANGE, HYDRAULIC SYSTEM .............................................................................4-36
OIL CHANGE, DIESEL ENGINE ....................................................................................4-38
TROUBLE SHOOTING
TROUBLE SHOOTING ...................................................................................................5-3

FUSES AND RELAYS ...........................................................................................................5-6
TOWING THE PAVER ..........................................................................................................5-7
MANUALLY RELEASING THE PARKING BRAKE .................................................................5-8
RELEASING THE HYDRAULIC DRIVE MOTORS TO RUN FREELY ......................................5-9
REMOVING PAVING MATERIAL FROM THE AUGER CHANNEL ........................................5-10
TECHNICAL DATA
TITAN 225 .........................................................................................................................6-2

GENERAL DATA ...........................................................................................................6-2
NOISE AND VIBRATION VALUES ....................................................................................6-4
DIMENSIONS ...............................................................................................................6-5
TITAN 325 .........................................................................................................................6-6
GENERAL DATA ...........................................................................................................6-6
NOISE AND VIBRATION VALUES ....................................................................................6-8
DIMENSIONS ...............................................................................................................6-9
CONSUMABLES
LIST OF FUEL OILS AND LUBRICANTS..................................................................................7-3
TORQUES FOR THREADED CONNECTIONS
TABLE OF TORQUES - ISO ................................................................................................8-2
GLOSSARY OF TERMS
ALPHABETICAL INDEX .........................................................................................................9-II
4 Track Paver Titan 225/325

INTRODUCTION
Track Paver Titan 225/325 0-1

INTRODUCTION
INTRODUCTION
This operating manual provides the operators and maintenance personnel on the job-site with
vital instructions, rules and criteria for operating and servicing the track paver model Titan 225/
325.
The operator must carefully read and understand the operating and maintenance manual
before operating the machine.
The operating manual contains the following chapters:
• INTRODUCTION
• Chapter 1, SAFETY
• Chapter 2, INSTRUMENTS AND OPERATING CONTROLS
• Chapter 3, OPERATING INSTRUCTIONS
• Chapter 4, MAINTENANCE
• Chapter 5, TROUBLE SHOOTING
• Chapter 6, TECHNICAL SPECIFICATION
• Chapter 7, FUEL AND LUBRICANT SPECIFICATIONS
• Chapter 8, TORQUE SPECIFICATIONS
If any part of this manual cannot be understood, contact your supervisor or local distributor.
The operators and maintenance personnel must understand the instructions contained in this
manual. This is an essential condition for working safely with the machine.
The correct machine operation, use and regular maintenance are also essential elements to
provide the highest performance and safety.
Remarks:No part of this operating manual may be reproduced, stored in

electrical data systems, processed, copied or published in any way
without prior written approval by the manufacturer. All rights for copying,
distribution and translation are reserved by the manufacturer.
Remarks:Machines may be illustrated in this manual equipped with

accessories.
0-2 Track Paver Titan 225/325

INTRODUCTION
PROCEDURE WHEN RECEIVING THE MACHINE

Your machine has been tested, accurately checked and prepared for shipment before leaving
the factory.
Upon receipt, check the machine for transport damage and missing parts.Use the shipping
documents sent with the machine and your purchase order to make a complete check of the
equipment.
Immediately inform the carrier if the machine is damaged or any parts are missing.He will tell
you what to do in cases of a claim.
DATA REQUIRED FOR ORDERING SPARE PARTS

An exact description of the model and serial number of your machine will facilitate a fast and
efficient response from our spare parts and service departments. Always have the model and
serial number of your machine close at hand when contacting your local spare parts and
service organisation.
We advise you to enter your machine data in the following lines so that they are always
available when required:
Model .......................................
Serial No. .................................
Year of manufacture.................
Engine Serial No. and type of engine.........................................
MACHINE IDENTIFICATION PLATE

The machine's identification plate (1) is located on the RH side of the machine at the rear of
the cover plate.
Illustration 1: Machine Identification Plate

INTRODUCTION
ENGINE IDENTIFICATION PLATE

The engine serial number is marked on the engine's identification plate (2).
Illustration 2: Engine Identification Plate
SAFEKEEPING THE OPERATING MANUAL AND FIRST AID BOX

Safely store the operating manual for the paver, the screed, the engine and for other options
in the storage compartment (3) for the first aid box. Renew any documents if they have
become illegible.
Remarks:Ensure the first aid box is always stored in this storage

compartment.The contents of the first aid box must be complete and in a
perfect condition. Regularly check the first aid box and renew any
missing or outdated items.
Illustration 3: Storage compartment for the first aid box and documentation

CHAPTER1- SAFETY

Chapter 1 SAFETY
SAFETY
Closely observe the recommended precautions and instructions for safely operating the
machine.
EXPLANATION OF THE SAFETY SYMBOLS

Safety symbols used in this manual. They
indicate a potential danger. Closely observe all
safety symbols to avoid fatal accidents, injuries
and damage to property and the environment.
The safety symbol "DANGER" indicates a

specially dangerous situation. Fatal accidents or
! DANGER serious injuries will occur if this symbol is not
observed.
(Red background)
The safety symbol "WARNING" indicates a
potentially dangerous situation. Fatal accidents
or serious injuries CAN occur if this symbol is not
! WARNING observed.
(Orange background)
The safety symbol "CAUTION" indicates a
potentially dangerous situation. Minor or medium
! CAUTION injuries or damage to the environment CAN occur
if this symbol is not observed.
(Yellow background)
The safety symbol "NOTICE" draws attention to
special assembly, operating or maintenance
NOTICE instructions not directly connected with danger.
(Blue background)
REMARKS: Remarks contain information for the efficient application of the machine.
PLEASE NOTE: Contains general information not connected with danger.

SAFETY Chapter 1
IMPORTANT GENERAL INFORMATION

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

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

put to unintended use. The manufacturer does not accept any liability
whatsoever for personal injury or damage to property if the machine is
put to an unintended use.

SAFETY Chapter 1
RESPONSIBILITIES OF THE USER / CONTRACTOR

The paver can only operate safely on the job-site if all necessary safety measures have been
taken. It is the responsibility of the user/contractor to plan implement all necessary safety
measures and ensure they are strictly observed.
As the user / contractor please ensure that:
• The machine is only operated for its intended use.

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

Chapter 1 SAFETY
• The contractor / owner must clearly delegate responsibilities to his personnel for
setting up, operating, servicing and repairing the machine. The operator must be
authorised to reject instructions from third persons which may jeopardise safety.

SAFETY Chapter 1
RESPONSIBILITIES OF THE PERSONNEL

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

Chapter 1 SAFETY
INSTRUCTIONS FOR SPECIAL HAZARDS
PRECAUTIONS FOR HANDLING HAZARDOUS GOODS

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

SAFETY Chapter 1
Material Precaution
Fuel is highly inflammable;when handling
Fuel
fuel, ensure there are no sparks or naked
flames in the far-reaching surroundings. Do
not smoke when refuelling.
Battery water
Gear oil

Chapter 1 SAFETY
PRECAUTIONS WHEN HANDLING GAS HEATING SYSTEMS

This chapter contains important instructions for the gas heating system on the paving screed
if your paver is equipped with this option.
! DANGER
Liquid gas is highly inflammable and burns explosively.Liquid gas is
heavier than oxygen, it sinks to the ground and displaces the oxygen.
This results in a danger of suffocation.
Closely observe the following safety instructions to avoid serious injury

and damage to property.
• The gas heating system may only be operated and serviced by qualified and
authorised personnel who have been specially trained in the operation and
maintenance of such systems.
• Ensure the complete gas heating system is checked by a fully qualified and
authorized person as follows:
— Before using the gas heating system for the first time, ensure that it is correctly
installed and has no gas leaks.
— Check the working safety of the system on completion of all maintenance and
repair work.
— Check the working condition, function, installation and gas leaks in the system if
it has been out of operation for more than one year.
• Your locally prevailing regulations for checking gas bottles still apply and are not
effected by this chapter.
• All gas connections must be checked for leakage and damage.Only use gas
detectors approved for gas systems.Searching for gas leaks with a naked flame is a
deadly peril and listening for escaping gas is not a safe method either. Do not use
the gas heating system if the hoses or connections are porous or damaged.
• Only operate the gas heating system in open and well ventilated areas.
• Protect the gas heating system from direct sun rays and other sources of heat (max.
50 °C). Cover the gas bottles with the canopies supplied with the paver.
• Close the valves on the gas bottles by turning them clockwise when the gas heating
system is not in use, e.g. during breaks in paving and when working on the system.
Disconnect, remove and properly store the gas bottles during longer standstill times.
• The gas heating system must be switched off during cleaning work.

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

Chapter 1 SAFETY
Gas Hose Routing
! CAUTION
The hose rupture protector (4) must never be removed or installed in
another position.
Illustration 2
Table 3: Schematic illustration of the propane gas heating system
1 Gas bottle with canopy 11 Ignition electrode

2 Stop valve, gas bottle valve 12 Thermo element
3 Medium pressure controller 13 Gas burner, basic screed
4 Hose rupture protector 14 Sieve
5 Distributor with 2 stop valves 15 Solenoid valve
6 High pressure hose 6x5 16 Regulator and stop valve
7 Start button 17 Ignition warning lamp
8 Stop button 18 Operating warning lamp
9 Safety valve 19 Gas burner, Vario screed section
20 Gas burner, 1000 mm screed
10 Burner
extension

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

Chapter 1 SAFETY
SAFETY PRECAUTIONS WHEN THE MACHINE TOUCHES LIVE ELECTRIC

CABLES
When paving, always keep the machine at an adequate safety distance to overhead electric
cables. If work must be carried out in the vicinity of overhead electric cables, then ensure there
is an adequate safety distance between the cables and parts and components on the paver.
! DANGER
Proceed as follows if the machine touches live electric cables:
• Remain seated on the operator's seat.

• Do not touch any operating controls or any other parts of the machine.
• Warn other persons not to touch the machine.
• Have the current switched off at source.
• Only leave the machine when you are absolutely sure that the damaged cable
is dead.

CHAPTER 2 - INSTRUMENTS AND
CONTROLS

Chapter 2 INSTRUMENTS AND CONTROLS
INSTRUMENTS AND CONTROLS
! WARNING
In the interest of your own safety and the safety of others, you must
thoroughly read and understand this chapter before operating the
machine.

INSTRUMENTS AND CONTROLS Chapter 2
MACHINE OVERVIEW
Illustration 1:
Table 1:
Pos. Description Function

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

OPERATOR'S PLATFORM
Illustration 2
Table 2:

1 Control panel cover Protects the control panel from rain and
dirt
2 Staple for padlock Protection against vandalism
3 Guide tube Cross-sliding the control column
4 Locking bolt hole Secures the control panel against unin-
tentional movement

OPERATOR'S SEAT
STANDARD SEAT
! CAUTION
Sudden movements of the seat will cause injuries. Ensure that all
adjusting levers lock into position after adjusting the seat. Only adjust
the seat when the machine is at a standstill.
Illustration 3:
Table 3:

1 Lever "operator's weight" Setting the operator's weight
2 Lever "seat to & fro" Longitudinal seat adjustment
3 Lever "backrest to & fro" Adjusting the backrest inclination
A-B Armrest Armrest raise and lower

DELUXE SEAT
! CAUTION
Illustration 4:
Table 4:

1 Lever "seat to & fro" Longitudinal seat adjustment
2 Lever "seat height / slope" Adjusting the seat height and slope
3 Lever "backrest to & fro" Adjusting the backrest inclination
4 Lever "operator's weight" Setting the operator's weight
5 Button switch "seat heating" (Option) Seat heating
Front LH switch: Seat heating ON /
OFF
Rear RH switch: Backrest heating ON /
OFF

CONTROL PANEL
Illustration 5:
Table 5:
Pos. Illustration Description Function

A1 Control lamp,engine Shows the temperature of the en-
oil temperature gine oil. The indicator needle must
be in the green range during oper-
ation. If the needle moves into the
red range, immediately stop the
engine and eliminate the cause of
overheating (e.g. engine overload-
ed, loss of coolant, dirty radiator).
A2 Fuel level indicator Shows the level of fuel in the fuel
tank.
The exact level can only be shown
when the machine is standing on
level ground.
A3 No function has been allocated to
this key


A4 Operating hour Shows the machine's number of
meter operating hours.
A5a Road lights No function has been allocated to

this key
A5b Flashing direction No function has been allocated to

indicators this key
A5c Battery charging Illuminates if the battery is not

lamp being charged due to a faulty gen-
erator or fault in the electrical sys-
tem.
A5d Control lamp engine Illuminates red if the oil pressure

oil pressure is too low (e.g. oil level too low).
Immediately switch off the engine.
An acoustic warning will sound 4
minutes after the red lamp illumi-
nates.
A6a Control lamp, engine Illuminates red if the coolant level
coolant level is too low. Let the engine run at
idling speed for a few minutes and
then switch it off. An acoustic
warning will sound at the same
time.Caution: Let the engine cool
down before checking the coolant
level. Also observe the "engine oil
temperature" warning (A1).
A6b Control lamp emer- Illuminates red when the emer-
gency STOP gency STOP button (A11) is
pressed.
A6c Control lamp Illuminates red if the hydraulic oil

hydraulic oil temper- temperature is too high. Immedi-
ature ately stop the paver. Let the
engine run at a medium speed
with the machine at a standstill to
cool down the hydraulic oil.


A6d Control lamp spring Illuminates red when the brake is
loaded brake applied
a) when the paver is switched OFF
b) when the ignition is switched
ON but the engine has not been
started
c) when the drive lever (A25) is in
the zero position and the engine is
running.
A7 Toggle switch, vibra- Select the operating mode for the
tion vibration.
Centre Position: Neutral, the vi-
brators are switched OFF.
LH Position (MAN): The vibrators
run permanently (for cleaning pur-
poses or adjusting the hydraulics).
RH Position (AUTO): The vibra-
tors are switched ON when the
drive lever (A25) is moved to the
forward travel position. The vibra-
tors are switched OFF when the
drive lever is returned to the centre
position. This mode is recom-
mended for paving work.
A8a Toggle switch, Select the operating mode for the
tampers tampers.
Centre Position: Neutral, the
tampers are switched OFF.
LH Position (MAN): The tampers
run permanently (for cleaning pur-
poses or adjusting the hydraulics).
RH Position (AUTO): The
tampers are switched ON when
the drive lever (A25) is moved to
the forward travel position. The
tampers are switched OFF when
the drive lever is returned to the
centre position. This mode is rec-
ommended for paving work.


A8b Potentiometer, Potentiometer for setting the
heavy duty tampers tamper frequency.
Potentiometer only with heavy
duty tampers (variable displace-
ment pump); refer to 227Page,
Pos. 2.
A9 Speed potentiome- Potentiometer for preselecting the
ter travelling speed.
The range of travelling speeds de-
pends on the position of the speed
stage toggle switch A13.
Toggle switch A13 on Pos. L:
0 - 16 m/min (paving speed range)
Toggle switch A13 on Pos. H:
0 - 60 m/min (transport speed
range)
A constantly controlled speed is
only possible at a potentiometer
setting of 0:7 m/min and higher.
A10 Control lamp, rapid Activate the rapid lubrication at
lubrication the end of daily paving work; the
control lamp illuminates during the
lubrication process.
A11 Emergency STOP Released: Normal operation

button
Depressed: All drives and move-
ments are stopped; the spring
loaded brake is applied.
A12 Release button for Depressed: Emergency STOP re-

emergency STOP leased.
The emergency STOP button
(A11) must be pulled upwards to
release the emergency stop.


A13 Toggle switch, Switch for selecting the required
speed stage selector speed stage.
switch
LH Position (L): Paving speed
(Low, 0 - 16 m/min)
RH Position (H): Transport speed
(High, 0 - 60 m/min)
The paver will automatically stop
when changing speed stages on-
the-run. Thereafter, turn the speed
potentiometer to start the paver
again.
A14 Toggle switch, turn- Used for turning the paver on the
ing on the spot spot.
This function can only be activated
when the drive lever (A25) is in the
zero position and the and the tog-
gle switch (A13) for the speed
stage selection has been moved to
the LH position "L" (paving speed
stage).
LH Position (0): neutral
Move the switch to the RH posi-
tion (I): Turning on-the-spot func-
tion is activated.
Rotate the steering potentiometer
(A26) to select the direction for
turning on-the-spot. The more you
rotate the steering potentiometer
(A26), the faster the paver will
turn.
this key


A16 Toggle switch, RH Toggle switch for altering the pav-
tow point ing thickness on the RH side.
The tow point can only be manual-
ly adjusted when the toggle switch
(A35) for the levelling system has
been moved to the MAN mode.
Centre Position: neutral
Move the switch to the rear (up-
wards): Increase the mat thick-
ness
Move the switch to the front
(downwards): Reduce the mat
thickness
A17 Toggle switch, RH Select the operating mode of the
auger operating RH auger.
mode
LH Position (MAX): Maximum au-
ger speed.In this position the au-
ger will rotate even when the
electronic control fails.
RH Position (PROP): Proportion-
al auger speed control according
to material requirements (control-
led by ultrasonic sensors)
A18 Toggle switch, RH RH auger ON / OFF control.
Auger ON/OFF con-
Centre Position: Auger is
trol
switched OFF.
Move the switch to the left
(MAX): The auger will rotate in the
mode selected with the toggle
switch A17.
Move the switch to the right
(AUTO): The auger will be propor-
tionally controlled by the ultrasonic
sensor.
A19 Toggle switch, RH RH conveyor ON / OFF.
conveyor operating
Centre Position: Conveyor is
mode
switched OFF.
LH Position (MAN): Conveyor is
manually switched ON and OFF.
RH Position (AUTO): The con-
veyor is controlled by the RH pad-
dle type control switch.


A22 Toggle switch, hop- Hopper wings open and close.
per wings
wards): Close the hopper wings.
(downwards): Open the hopper
wings.
Mechanically secure the closed
hopper wings with the locking bolts
when transporting the paver.
A21 Toggle switch, Determine the direction of rotation
Auger reverse mode on both auger halves.
Centre Position: neutral, the au-
ger halves will convey the material
outwards on both sides.
LH Position: Both augers will con-
vey the material to the LH side.
RH Position: Both augers will
convey the material to the RH
side.
A22 Button switch, warn- Press the button to sound the
ing horn warning horn.
Sound the warning horn before
moving the paver to warn other
persons in the danger zone.
A23 Control lamp, rotary Flashes if the rotary sensor or its
sensor wiring fails on the RH or LH trans-
mission gear.


A24 Ignition switch Starting and stopping the engine
From left to right:
Position „P“: Parking position
(P), the ignition key can be re-
moved
Position „0“: Engine cut-out (be-
fore stopping the engine, let it run
for approx. 5 minutes without load
at a higher speed to cool down).
Position „1“: Switch on the igni-
tion; the control lamps will illumi-
nate
Position „2“: Start the engine
To start the engine, the drive lever
(A25) must be in the neutral posi-
tion.
A25 Drive lever For driving the paver forward or
backward up to the speed set on
the speed potentiometer (A9).
Release the drive lever by placing
two fingers underneath and either
side of the knob and lifting it gen-
tly.
Centre Position: neutral, the
pave is at a standstill and the
spring brake is applied.
Gently move the drive lever for-
wards as far as it will go: The
paver travels forwards
Gently move the drive lever
backwards as far as it will go:
The paver travels backwards
All automatic functions (except the
conveyors) can only be activated
when the paver is travelling for-
wards.


A26 Steering potentiom- For steering the paver
eter
Centre Position: The paver trav-
els straight ahead.
Rotate to the left: The paver will
travel in a left turn
Rotate to the right: The paver will
travel in a right turn
A27 Toggle switch, Screed assist ON / OFF.
screed assist
The screed assist prevents the
(Option)
screed sinking downwards during
paving work and improves the
paver's traction.
If required, a variable pressure be-
tween 10 and 50 bar can be ap-
plied to the screed transport
cylinders.
This pressure counteracts the
weight of the screed and prevents
it sinking into paving material with
a low bearing capacity. This option
does not effect the screed's float-
ing behaviour; the screed will bear
down on the material with a re-
duced load.
LH Position (ON): Screed assist
is switched ON
RH Position(OFF): The screed
assist is switched OFF


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


A31 Toggle switch, Screed raise and lower
Screed raise / lower
Move the switch to the
rear:Screed raise
(downwards): Screed lower
A32 Toggle switch, LH Select the operating mode of the
auger operating LH auger.
mode
LH Position (MAX): Maximum au-
ger speed.
RH Position (PROP): Proportion-
al auger speed control according
to material requirements.
A33 Toggle switch, LH LH auger ON / OFF control.
Auger ON/OFF con-
Centre Position: Auger is
trol
switched OFF.
Move the switch to the left
(MAX): The auger will rotate in the
mode selected with the toggle
switch A32.
Move the switch to the right
(AUTO): The auger will be propor-
tionally controlled by the ultrasonic
sensor.
A34 Toggle switch, LH LH conveyor ON / OFF.
conveyor operating
Centre Position: Conveyor is
mode
switched OFF.
LH Position (MAN): Conveyor is
manually switched ON and OFF.
RH Position (AUTO): The con-
veyor is controlled by the LH pad-
dle type control switch.


A35 Toggle switch, Lev- Levelling system control.
elling system
Centre Position: The levelling
system is switched OFF.
LH Position (MAN): The levelling
system will function when the ma-
chine is paving and at a machine
standstill. This permits the mat
thickness to be corrected using the
toggle switches (A16) for the RH
tow point and (A37) for the LH tow
point. We recommend to use this
position only for setting up the lev-
elling system at the start of paving
work.
RH Position (AUTO): The level-
ling system will control the mat
thickness during paving work.This
position is recommended for pav-
ing.
this key
A37 Toggle switch,LH Toggle switch for altering the pav-

tow point ing thickness on the LH side.
The tow point can only be manual-
ly adjusted when the toggle switch
(A35) for the levelling system has
been moved to the MAN mode.
wards): Increase the mat thick-
ness
(downwards): Reduce the mat
thickness


A38 Lever, engine speed Throttle lever for engine speed.
control
Move the lever upwards: In-
crease the engine speed
Move the lever downwards: Re-
duce the engine speed

EXTERNAL CONTROL PANELS

The external control panels are mounted mirror inverted at the rear of the paver on the LH and
RH sides.
Illustration 6:
Table 6:

B1 Button switch, Increase the angle of attack on the
Increase mat thick- LH and RH side of the screed to in-
ness crease the mat thickness.
Ensure the tow points are not ad-
justed to opposite limit stops (one
tow point to the upper and one tow
point to the lower limit stop). This
will cause undue torsion and twist-
ing on the screed. The maximum
permissible difference in height
between the LH & RH mat thick-
ness scales must not exceed 100
mm.
Never operate the tow point ad-
justment when the screed is raised
and secured in the transport locks
otherwise damage will occur to the
locking device.


B2 Button switch, Reduce the angle of attack on the
Reduce the mat LH and RH side of the screed to
thickness reduce the mat thickness. Refer to
B1.
B3 Button switch,over- For overmodulating the RH re-

modulating the spectively the LH auger.
augers
Use the overmodulating function if
you require a higher head of mate-
rial in the auger channel for a short
time (e.g. just before extending the
Vario screed).
The respective auger will rotate at
maximum speed as long as you
keep the button switch depressed.
Condition: Pressure switch B7 is
pulled upwards.
B4 Button switch,Vario Extend the LH / RH Vario
screed extend screed.The warning light B8 will
flash when the Vario screed is
extended.
B5 Button switch, Vario Retract the LH / RH Vario screed.

screed retract The warning light B8 will flash
when the Vario screed is
extended.
B6 Button switch, warn- Press the button to sound the
ing horn warning horn.
B7 Pressure switch The material flow (conveyors and

STOP material flow augers) can be stopped separately
on both sides if the head of materi-
al in the auger channel is too high.
Released: Normal operation
Depressed: LH respectively RH
conveyor and auger will be
stopped.
B8 Warning light Vario Flashes when the Vario screed is
screed extend / extended or retracted.
retract

STORAGE COMPARTMENTS
Illustration 7:
Table 7:
Pos. Description Location

1 Tool box tray Underneath the deck plate on the oper-
ator's platform
2 Compartment for First aid box and RH side on the operator's platform
operating manual

FUEL TANK
Illustration 8:
Table 8:

1 Filler cap Topping up with Diesel fuel; new pavers
are supplied with the ignition key for the
ignition switch (A24) fastened on the
inside of the filler cap

CENTRAL LUBRICATION SYSTEM (OPTION)

The paver can be equipped with a central lubrication system located inside the RH side door;
the system lubricates the paver at specified intervals.
! CAUTION
Observe the following:
• The central lubrication system functions automatically.Nevertheless, check at

regular intervals and ensure that lubricant emerges from the grease points.
• The grease container must never run empty otherwise the pump must be deareated.
Illustration 9
Table 9:

1 Central lubrication system Lubricates the basic auger, conveyor
drive shaft and conveyor idler shaft as
well as the bearing arms
2 Lubricating point Connection for the grease gun (4)
3 Pressure relief valve Safety valve
4 Grease gun Filling the grease container with lubri-
cant

MAT THICKNESS SCALES

The mat thickness scales show the approximate thickness of the mat being paved. Instructions
for mechanically altering the screed's angle of attack as well as for adjusting the mat thickness
are included in the operating manual for your paving screed.
Illustration 10:
Table 10:

1 Mat thickness scales Indicates the approx. paving thickness

EMULSION SPRAYING SYSTEM (OPTION)
! CAUTION
Protect the environment by using a washdown point with a separator for
cleaning the paver. If this is not possible on your job-site, then the
cleaning solvent must be collected in a suitable container. Do not allow
the cleaning solvent to seep into the ground.
Fire hazard Do not use flammable cleaning solvents. Only start spraying
the cleaning solvent after the burner chambers have cooled down
(approx. 10 minutes after switching off the heating system).
Illustration 11:
Table 11:

1 Stop valve Hose connection with ball cock
2 Spraying lance Spraying lance with nozzle
3 Level indicator Shows the level of cleaning solvent in
the tank
4 Filler cap Top up with non-flammable cleaning
solvent

POTENTIOMETERS FOR VIBRATORS AND TAMPERS

Illustration 12:
Table 12:

1 Potentiometer, vibrators Setting the vibrators
Rotate clockwise: reduce the vibrator
speed
Rotate anti-clockwise: increase the vi-
brator speed
2 Potentiometer, Tampers“ (This potenti- Setting the tampers
ometer is installed with the standard
Rotate clockwise: reduce the tamper
tampers without variable displacement
speed
pump). The potentiometer for the heavy
duty tampers is located on the control Rotate anti-clockwise: increase the
panel -refer to 210Page, Pos. A8b) tamper speed

SWITCH OFF THE LEVELLING CYLINDERS IN CASE OF

BREAKDOWNS
! CAUTION
Always close both ball cocks on the levelling cylinders on both sides of
the paver. If you only switch off the levelling cylinder on one side of the
paver, the screed will be subject to excess torsion and will be damaged.
Illustration 13:

Table 13:

1 Ball cock, levelling cylinder Switch off the hydraulic circuit for the RH
or LH levelling cylinder n case of a
breakdown (Location:on the RH and LH
levelling cylinders).
Lever position vertical (as illustrat-
ed): Normal position, the ball cock is
open, the hydraulic is switched on and
the levelling cylinder is ready for opera-
tion
Lever position horizontal: The ball
cock is closed, the hydraulic circuit is
blocked; the levelling cylinder is
switched off. Levelling is not possible.

SCREED HEATING SYSTEM (OPTION)

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

The following procedure must be strictly observed to ensure a burner run-down.

Machines equipped with standard gas burners
• before switching off the paver's ignition, ensure that the toggle switch for the standard
gas burners is moved to Pos. ON (I) to ensure a burner run-down.
Machines equipped with temperature controlled gas burners (Thermo-Control)
• before switching off the paver's ignition, ensure the operating mode switch is moved
to the Pos. „AUTO“ or „MAN“ to ensure a burner run-down.
Illustration 14:
Table 14:

1 Gas bottle connection Gas hose with pressure reducer
2 Gas bottle tensioning belt Securing the bottle against falling over

ELECTRONIC LEVELLING SYSTEM (OPTION)

When using an automatic levelling system you will obtain the best possible surface evenness.
Using a grade control will require a reference surface (kerbstone, adjacent lane or tensioned
levelling wire).
We do not recommend using a levelling system for paving a wearing course if the previous
binder course is smooth and level.
Further information on the application of the optional levelling system is included in a separate
instruction manual.
Illustration 15
Table 15:

1 Support, Moba controller For installing the optional Moba control-
ler
2 Assembly plate Electronic levelling sys- Assembly plate for the optional elec-
tem tronic levelling system

ELECTRICS
BATTERY MASTER SWITCH
! CAUTION
Switch off the power supply with the battery master switch:
• before all maintenance and repair work on the paver to avoid short circuits.
• at the end of paving work to ensure all users have been switched off.
Illustration 16:
Table 16:

1 Battery Master Switch Switch off the power supply at the end of
work
Vertical position: Power supply
switched on (illustration refers)
Horizontal position: Power supply is
switched off (as an additional anti-theft
measure, remove the plastic key from
the master switch in this position at the
end of work).

WORKING LIGHTS
Illustration 17:
Table 17:

1 Working lights Illuminating the front and rear working
area of the paver
2 Xenon floodlights (Option) Illuminating the front and rear working
area of the paver
3 Warning beacon (Option) To improve safety in the working
area;ON / OFF switch located on the
roof strut
4 Additional Working Lights (Option) For illuminating the auger channel

SOCKETS / FUSES ON THE PAVER'S LH REAR WALL
Remarks: Ensure the sockets are closed with the protective caps when
not in use. This will avoid moisture and dirt damaging the sockets.
Illustration 18:
Table 18:

1 24-V socket Socket for the levelling system / LH
slope controller
2 24-V socket Socket for the working lights or addi-
tional working lights
4 Fuse box Fuses F83 to F90 (refer to the allocation
of fuses in the switch cabinet on the
control column)
5 24-V socket Socket for the gas burners on the Vario-
matic screed - basic width
6 24-V socket Socket for the control cable; the socket
must be connected during paving work
otherwise the LH auger will not function

SOCKETS ON THE PAVER'S RH REAR WALL
Illustration 19:
Table 19:
Pos. Function FUNCTION

slope controller

SOCKETS ON THE LH AND RH EXTERNAL CONTROL PANELS
Illustration 20:
Table 20:
Pos. Function FUNCTION

and/or RH grade control
3 24-V socket Socket for the ultrasonic sensor on the
RH auger

SWITCH CABINET ON THE OPERATOR'S PLATFORM
Remarks: Please note that the switch cabinet may only be opened for
short periods to perform any work. This will avoid moisture and dirt
damaging the sockets.
Illustration 21:
Table 21:

1 Fuses Please refer to the overview of fuses
(G2) on the inside of the switch cabinet
door for the allocation of fuses
2 Plan of fuses and relays Allocation of fuses and relays
3 Toggle switch, emergency control The paver can be operated in emer-
gency control if a fault occurs in the
electronics
Top position: Emergency operation
Lower position: Normal operation

SWITCH CABINET ON THE PAVER'S REAR WALL
Remarks: Please note that the switch cabinet may only be opened for
short periods to perform any work. This will avoid moisture and dirt
damaging the sockets.
Illustration 22:
Table 22:

1 Switch cabinet, screed heating Setting the temperature on the screed
heating
2 Switch cabinet No operation required. Do not alter the
settings! Refer to the circuit diagram for
functions.

SOCKETS ON THE PAVER'S REAR WALL
Illustration 23:
Table 23:

1 Connection, hydraulic crown control Refer to the documentation for the
screed
2 Socket Not relevant for operation

CHAPTER 3 - OPERATION

Chapter 3 OPERATION
OPERATION
! WARNING
Before operating the machine, thoroughly read and understand Chapter
1 “Safety”, Page 1-2 and Chapter 2 “INSTRUMENTS AND CONTROLS”,
Page 2-2.
Improper use and unexpected movements of the paver and moving parts
can cause serious injuries and fatal accidents.
! CAUTION
The engine output must be reduced if the Diesel engine is operated at
temperatures of around 40° C and altitudes of around 1000 metres. The
reduction of engine output may only be carried out by the engine
manufacturer.

OPERATION Chapter 3
IMPORTANT INSTRUCTIONS FOR OPERATION

Strictly observe the following instructions when operating your paver:
• Use the handrails and steps when climbing up onto and leaving the machine and
keep the working area free from dirt and ice.
• Only put the machine into operation when all protective and safety devices are
correctly installed and fully functional (e.g. working lights, removable safety systems,
noise protection devices and exhaust system).
• The operator must be well acquainted with his working surroundings. Observe any
obstructions and other potential hazards in the working area and be aware of these
sources of danger.
• The paving crew must be acquainted with and use any hand signals required for the
working process. Furthermore, a responsible person must determine the hand
signals to be used.
• The operator must not leave the operator's platform when the engine is running. Do
not jump onto or down from the machine when it is moving.
• Observe all warning and control lamps and indicators when stopping and starting the
machine and be aware of any irregularities.
• Switch on the working lights during poor visibility and twilight hours.
• Before putting the machine into motion, ensure there are no persons or obstructions
in the direction of travel or within the danger zone of the screed. Observe the paving
width on both sides of the extended Variomatic screed.
• Use extreme care and added caution when working on narrow job-sites or paving
jobs with a high volume of traffic.
• Use the drive lever and not the engine throttle lever to control the machine's
speed.Do not accelerate a cold engine to a higher speed.
• Ensure there is adequate headroom before driving the machine through bridges and
tunnels, underneath overhead cables and across bridges.
• Keep an adequate safety distance to trenches, ditches and slopes.
• Sound the warning horn to warn persons in the vicinity before driving off and putting
machine parts into motion. Give other persons sufficient time to leave the danger
zone before moving the machine.
• Before leaving the operator's platform, secure the machine against unintentional
movement and unauthorised access. Remove the ignition key.
• Park the machine on firm ground with sufficient bearing capacity.

Chapter 3 OPERATION
APPLICATION SPECIFIC SAFETY INSTRUCTIONS
PAVING IN TUNNELS
• Ensure there is adequate ventilation

• Ensure there is sufficient lighting in the tunnel.
• Ensure suitable fire-fighting precautions have been taken.
PAVING IN THE VICINITY OF OVERHEAD ELECTRIC CABLES
• Ensure there is always an adequate safety distance between the paver and
overhead electric cables. Otherwise a deadly conduction of electric current is
possible. The safety distance depends upon the voltage in the overhead cables and
the weather conditions.A conduction of current is possible at a distance of several
metres at a high voltage and damp air.
• Switch off the power in the overhead cables if it is not possible to keep an adequate
safety distance.
• If the machine makes contact with an electric power cable in spite of taking these
precautions, refer to the procedures outlined in Chapter 1 “Safety precautions when
the machine touches live electric cables”, Page 1-14.
PAVING IN CONTAMINATED AREAS
• Ensure the paving crew is not exposed to health risks when working in the vicinity or
in contaminated areas such as waste disposal dumps etc.
• Ensure the paving crew is wearing the required protective clothing.
• Thoroughly clean the paver before leaving the contaminated area.
PAVING IN THE VICINITY OF RAILWAY LINES
• Paving in the vicinity of railway lines with passing rail traffic is subject to increased
danger which can lead to fatal accidents.
• Only start work after obtaining permission from the railway authorities and after all
necessary safety measures have been taken.
• Pay continuous attention to the railway traffic and to the railway staff´s instructions,
in order to immediately remove machine and persons out of the danger zone.
• Ensure there is always an adequate safety distance between the paver and
overhead electric cables. Otherwise a deadly conduction of electric current is
possible. The safety distance depends upon the voltage in the overhead cables and
the weather conditions. A conduction of current is possible at a distance of several
metres at a high voltage and damp air.

OPERATION Chapter 3
PAVING ON SLOPES
• Special safety precautions must be taken, such as securing the paver with a winch
cable, when working on slopes where there is a danger of the machine toppling over
or sliding away.
PAVING ON BRIDGES
• Ensure the weight bearing capacity of the bridge is sufficient to carry the weight of
the paver and other machinery and equipment required for paving work.
• Take the vibration effect of the screed into consideration.

Chapter 3 OPERATION
COMMISSIONING THE PAVER
CHECK BEFORE COMMISSIONING THE PAVER
! WARNING
Only put the machine into operation when you are absolutely sure that it
is a perfect working condition. It is not permitted to use the machine if
you know it is faulty. Rectify the faults or have them repaired by a service
technician or your local distributor.
Thoroughly check the machine before putting it into operation.
1. Ensure that all daily maintenance work is carried out.(refer to ”Daily procedure
at the end of paving work”, page 3-61.) If necessary, top up fluids and complete
maintenance work.Pay particular attention to:
• Cleanliness of all machine components

• Fuel level
• Coolant level
• Engine oil level
2. Check the complete machine for loose, worn and missing parts. This specially
applies to all safety devices.Renew any parts if necessary.
3. Check the following components for leakage: Gas heating system, fuel tank,
fuel lines, hydraulic lines, hoses, filler necks, drain plugs, pressure valves,
exhaust pipe, engine and components installed underneath the paver.
4. Ensure that the first aid box and operating manual are stored on the machine.
5. Remove all items not required for paving work.
6. Clean the paver.In particular, remove all dirt, water or ice from the operator's
platform and in the vicinity of the external control panels which may pose a slip
hazard.
7. Carry out the work described in the following sections and ensure the work has
bee performed correctly.

OPERATION Chapter 3
SWITCHING THE POWER SUPPLY ON AND OFF

The power supply from batteries (2) is switched OFF with the battery master switch (1). The
engine cannot be started if the power supply is switched OFF.
Remarks: Switch off the power supply and remove the plastic key from
the battery master switch:
• before starting maintenance and repair work to avoid short circuits and the paver
being started during work.
• at the end of paving work as an additional anti-theft and anti-vandalism measure.
Illustration 4
1. Open the paver's RH side door. Ensure the retainer catch locks into position
and prevents the door from closing.
2. Actuate the battery master switch 1:
• To switch ON the power supply: Turn the plastic key to the vertical position (as
illustrated).
• To switch OFF the power supply: Turn the plastic key to the horizontal position
(90° anti-clockwise).
3. Release the retainer catch and close the door.

Chapter 3 OPERATION
SETTING UP THE OPERATOR'S PLATFORM

A correctly set up operator's platform which provides the operator with an optimum view of the working
area is a significant step towards avoiding accidents and damage to property.
! CAUTION
Only start the paver after the operator's platform has been set up to
ensure an optimum view of the working area and all platform components
have been safely secured.
During operation, all loose items must be removed from the paver as they
can cause serious accidents.

OPERATION Chapter 3
Raising and Lowering the Sun Roof

The height of the paver can be reduced for transport on a vehicle by lowering the sun roof.
! CAUTION
The sun roof must be raised and safely secured against lowering with the
bolts/nuts (2 and 3) for paving work. Otherwise it is not permitted to
operate the paver on account of the restricted headroom.
Before lowering the roof, the windscreen (if fitted) must be raised (refer to
Chapter 3 “Windscreen (Option), Raising and Lowering”, Page 3-13).
After the roof has been lowered, it must be secured against raising with
the bolts/nuts 3.
Illustration 5

Chapter 3 OPERATION
Raising the Sun Roof:
1. Remove both safety bolts (2) from the lower hinge joints on both front roof
struts; these bolts have been placed there for safe keeping.
2. Remove the safety bolt (3) from the lower hinge joint on one of the rear roof
struts (section A, position 4). Loosen the nut on the bolt 3 on the other rear roof
strut.
3. Now stand on the steps to the operator's platform, pull the roof slightly
downwards with one hand and use the other hand to remove the remaining bolt
3. Push the roof upwards until it is fully raised.
4. Fit the safety bolts 3 into the lower hinge joints on the rear roof struts.
5. Fit the lower safety bolts 2 to the lower hinge joints on both front roof struts.
6. Lower the front windscreen if installed on your on the paver (refer to Chapter 3
“Windscreen (Option), Raising and Lowering”, Page 3-13).
Lowering the Sun Roof:
1. Move the control column to the centre of the platform and lock it in this position
(refer to the safety decal).
2. Raise the front windscreen if installed on your on the paver (refer to Chapter 3
“Windscreen (Option), Raising and Lowering”, Page 3-13).
3. Remove the safety bolts 2 from the lower hinge joints on both front roof struts.
4. Remove the safety bolts 3 from the lower hinge joints on the rear roof struts.
5. Now stand on the steps to the operator's platform, grip the handrail with one
hand to steady yourself and carefully pull the roof to the rear with the other
hand. Caution! Danger of Injuries: A certain amount of force will be required
to start the roof lowering; thereafter, the roof will lower easily, cushioned by the
hydraulic springs. Take care not to bump your head when lowering the roof.
6. Secure the roof against raising by fitting the bolts 3 in the holes 4 and fastening
the nuts (section A, position 4).
7. Replace the safety bolts with nuts 2 into both front roof struts for safe keeping.

OPERATION Chapter 3
Exhaust Pipe, Fitting and Removing

The height of the paver must be reduced for transport on a vehicle. For this reason, remove
the exhaust pipe.
! CAUTION
Do not start the paver without the exhaust pipe, otherwise poisonous
emission will be a health hazard to personnel in the vicinity.
Illustration 6
1. Insert or remove the exhaust pipe from the pipe connection 1.

Chapter 3 OPERATION
Fitting the Side Curtains

The side curtains (1) protect the operator from rain and wind. Roll the side curtains up during
good weather to obtain a better all round view.
Illustration 7
Fitting the Side Curtains (1): Fit the side curtains (1) to the sun roof (2) and the roof struts
(3) as illustrated.
Removing the Side Curtains (1): Loosen and remove the side curtains (1) from the sun roof
(2) and roof struts (3) as illustrated.

OPERATION Chapter 3
Windscreen (Option), Raising and Lowering

The windscreen is raised to the rear and underneath the roof for transport.The windscreen is
divided in the middle so that first one half and then the other half is raised.
Raising the Windscreen:
1. Loosen the centre bolt connection.

2. Loosen the outer bolt connection on the outer edge of one half windscreen.
3. Raise the windscreen half up and underneath the roof and secure the outer bolt
in the hole provided in the retainer plate.
4. Repeat step 3 with the other half of the windscreen.
5. Connect both raised halves of the windscreen in the middle with the connecting
bolt.
6. Ensure both windscreen halves are safely secured in the raised position.
! CAUTION
It is absolutely essential that the circlip is moved to the front as long as
one or both windscreen halves are raised underneath the roof.
Lowering the Windscreen:
1. Loosen the centre bolt connection.

2. Loosen the outer bolt connection on the outer edge of one half windscreen.
3. Lower one half of the windscreen downwards and secure the outer bolt in the
hole provided in the retainer plate.
4. Repeat step 3 with the other half of the windscreen.
5. Connect both raised halves of the windscreen in the middle with the connecting
bolt.
6. Ensure both windscreen halves are safely secured in the lowered position.

Chapter 3 OPERATION
Operator's Platform, Extending and Retracting

The operator's platform can be extended on both sides to improve the vision into the working
area. The platform must be retracted for transport on a vehicle to minimize the paver's width.
Illustration 8
Extending the Platform:
1. To extend the platform, release the locking devices (2) on the side of the paver
required and lower the side plate (1).
2. To extend the roof, loosen the wing nut at Pos. 3 and unscrew the threaded bolt
by a few turns. Remove any existing transport safety measures (e.g. cable
straps).
3. Extend the roof outwards by max. 50 cm.
4. Tighten up the threaded bolt at Pos. 3 and secure with the wing nut.
Retracting the Platform:
1. To retract the roof, loosen the wing nut at Pos. 3 and unscrew the threaded bolt
by a few turns.
2. Retract the roof as far as it will go.
3. Tighten up the threaded bolt at Pos. 3 and secure with the wing nut.
4. To retract the platform, hinge the side plate 1 upwards and secure it with both
locking devices 2.

OPERATION Chapter 3
Seat Console, Extending and Retracting

After extending or retracting the platform, you can extend or retract the seat console.
Illustration 9
1. Pull the lever 2 upwards until it is free of the hole 3.

2. Extend or retract the seat console 1 until it locks into the required position.
3. Ensure the lever bolt 2 has securely locked into the hole 3.

Chapter 3 OPERATION
Control Column, Cross Sliding

Position the control column according to the required sitting position. The control column may
only be positioned in the locking holes provided on the platform's floor plate (LH or RH side on
the extended or retracted platform). All other positions between these locking holes are not
permitted.
Illustration 10
1. Slightly tilt the control column to the rear (raise slightly) and cross slide it to the
required position on the guide rail depending on which side you have the best
view of the working area.
2. Lower the control column so that it locks into the hole 4 on the platform floor
plate. Ensure the control column has safely locked into position.
3. Open the cover 1 on the control panel (if necessary, remove the padlock 2).

OPERATION Chapter 3
Operator's Seat, Adjusting (Standard Seat)
! CAUTION
Danger of injuries caused by sudden movements of the seat. Ensure that
all adjusting levers lock into position after adjusting the seat. Only adjust
Illustration 11:
1. To and Fro Adjustment: Pull the lever (2) upwards to unlock the seat. Hold the
lever up and adjust the seat to the required position. Release the lever (2) to
lock the seat in position.
2. Backrest Adjustment: Pull the front lever (3) upwards. Sit on the seat and use
the weight of your body to adjust the seat's position. Thereafter, release the
lever (3) to lock the seat in position.
3. Operator's Weight Adjustment: The weight setting can be varied with the
lever (1). The number on the scale should correspond to the weight of the
operator. The seat suspension is now set to the weight of the operator. First
press the lever to the lowest position to return it to the upper position.
4. Armrest Adjustment: Tilt the armrests to position A or B.

Chapter 3 OPERATION
Operator's Seat, Adjusting (Deluxe Seat)
! CAUTION
Illustration 12:
1. To and Fro Adjustment: Pull the bar lever (2) upwards to unlock the seat. Hold
the bar lever up and push the seat to the required position. Release the bar
lever to lock the seat in position.
2. Height and Slope Adjustment: Unlock the seat by pulling the lever (3) on the
left-hand side upwards. Sit on the seat and use the weight of your body to
adjust the seat's position. Thereafter, release the lever (3) to lock the seat in
position.
3. Backrest Adjustment: Pull the lever (4) on the left-hand side upwards. Sit on
the seat and use the weight of your body to adjust the seat's position.
Thereafter, release the lever (4) to lock the seat in position.
4. Operator's Weight Adjustment: The seat's suspension can be adjust to the
weight of the operator by turning the knob (1) at the front of the seat. The
number which appears in the window must correspond to the weight of the
operator. The seat suspension is now set to the weight of the operator.
5. Armrest Adjustment: By turning the knob (5), you can adjust the height and
angle of the armrests.
6. Seat Heating (Option): Switch the seat heating on and off with the switch (6).
The engine must be running to operate the seat heating.

OPERATION Chapter 3
STARTING THE ENGINE
! CAUTION
Only start the engine if:
• the paver is in a perfect functional condition and equipped with all safety devices
supplied with the machine.
• the operating personnel are fully qualified and fully acquainted with all controls and
instruments.
• no repair or maintenance work is being carried out on the paver.
• the platform is correctly equipped and set up, no access doors are open and no loose
objects are on the paver.
• the surroundings are well ventilated.

Chapter 3 OPERATION
Starting the Engine with the Starter Batteries
Illustration 13
1. Return all operating elements on the control panel to the zero position: Toggle
switches to „0“ or „OFF“ position, drive lever (A25) to the centre neutral
position, speed potentiometer (A9) and steering potentiometer (A26) to „0“.
2. Check that the emergency STOP button (A11) has been pulled upwards and
the drive lever (A25) is in the centre neutral position. If the control lamp
"emergency STOP" (A6b) illuminates, press the button switch (A12) to release
the emergency STOP.
3. Move the engine throttle lever (A38) to 1/4 speed.
4. Start the engine:
• Insert the ignition key in the ignition switch (A24). (The paver is supplied with the
ignition key fastened to the inside of the filler cap).
• Turn the ignition key to position 1.
• Turn the ignition key to position 2 "Engine Start". Release the key as soon as the
engine starts.
Remarks: Do not actuate the starter for more than 20 seconds as the
starter motor will overheat. If the engine cannot be started at the first
time, wait for 2 to 3 minutes before attempting another start.
5. With the exception of the spring loaded brake (A6d), check and ensure that all
other control lamps are extinguished. If not, immediately switch off the engine
and rectify the fault.
6. Move the engine throttle lever (A38) to the lowest speed.
7. Let the engine run warm for a short time to bring the hydraulics and the engine
up to operating temperature. However, ensure the engine does not run for more
than 10 minutes at idling speed.

OPERATION Chapter 3
Jump Starting the Engine
! WARNING
Strictly observe the following instructions when jump starting the engine.
Ignoring these instructions will lead to accidents, serious injuries and
possibly death.
• Exercise extreme caution when jump starting the engine.

• Wear protective goggles when working on or in the vicinity of batteries.
• Lead acid batteries develop explosive gases when being charged. Keep naked
flames and sparks away from batteries.
• Do not touch either machine during the jump starting process.
• Do not start the machine by connecting the jumper cable to the starter motor or
starter solenoid switch because this will bridge over the safety device installed on the
machine. There is also a danger of the machine being put into motion and running
over the people carrying out the jump start.
• Never attempt to jump start a machine with frozen batteries as this will cause the
batteries to explode.
• Before jump starting the machine, disconnect all electronic equipment (e.g. levelling
system) from the power supply as this will be damaged by peaks in the voltage.

Chapter 3 OPERATION
Illustration 14:
1. Open the paver's RH side door.

2. Check and ensure that the battery master switch(1) is turned to the ON position
(horizontal).
3. Connect one end of the jumper cable to the plus (+) terminal on the external
battery and the other end to the plus (+) terminal on the machine's flat battery
(2).
4. Then connect one end of the jumper cable to the minus (-) terminal on the
external battery and the other end to the minus (-) terminal on the machine's
flat battery (2).
5. Now start the engine (Chapter 3 “Starting the Engine with the Starter Batteries”,
Page 3-20)
6. Remove the jumper cable which connects the minus (-) terminals.
7. Then remove the jumper cable which connects the plus (+) terminals.
8. Close the side door.

OPERATION Chapter 3
STOPPING THE ENGINE
! CAUTION
Immediately stop the engine if:
• a dangerous situation occurs.

• the operator leaves the paver.
• any work must be carried out on the paver.
Press the emergency STOP button (A11) in dangerous situations to stop

the engine and all moving components.
Illustration 15
1. Return all operating elements on the control panel to the zero position: Toggle
switches to „0“ or „OFF“ position, drive lever (A25) to the centre neutral position,
speed potentiometer (A9) and steering potentiometer (A26) to „0“.
2. Move the engine throttle lever (A38) to the lowest speed. Depending on the
previous load, let the engine run for a time to cool down (but not longer than 10
minutes).
3. Turn the key in the ignition switch (A24) to the "P" position (Park).
4. Remove the key before leaving the paver.

Chapter 3 OPERATION
STARTING AND STOPPING THE PAVER
! CAUTION
Observe the following before driving the paver:
• It is not permitted to operate the paver on public roads.

• Secure or remove any loose objects on the paver.
• Check the fuel level on the control panel. Refuel if necessary (Chapter 3 “Refuelling
the Paver”, Page 3-30)
• Switch on the working lights during poor visibility and twilight hours.
• Inspect and become acquainted with the immediate working area. Pay particular
attention to all possible hazards such as potholes in the road surface, slopes and
inclinations, underground culverts, manhole covers, drainage ditches, kerbstones
and/or roads.
• The maximum permissible inclination is a slope of 25%.
• Before putting the machine into motion, ensure there are no persons or obstructions
in the direction of travel or within the danger zone of the screed. Observe the paving
width on both sides of the extended Variomatic screed.
• Sound the warning horn before driving off or changing directions.
• When steering track mounted machines, the front and rear will swing out when
cornering. Therefore, keep a safe distance to persons, buildings and other obstacles.

OPERATION Chapter 3
DRIVING THE PAVER ON ROADS AND JOB-SITES
! CAUTION
When driving the paver on roads and job-sites there is a danger of fatal
accidents and serious damage. Closely observe the following when
driving the paver:
• It is not permitted to operate the paver on public roads.

• Observe the extended width of the screed when transporting the paver on job-sites.
• If necessary, ballast must be placed in the hopper to act as a counter weight to the
screed. Ballasting is not necessary if the paver is driven at a very slow speed.
• When driving the paver on the job-site, disconnect the gas bottles and fit the
protective caps (Chapter 2 “Screed Heating System (Option)”, Page 2-30).
• Switch on the warning beacon and mount warning plates if required by your locally
prevailing traffic code.
Illustration 16
1. Close and lock the hopper wings (Chapter 3 “Hopper Wings, Open and Close”,
Page 3-36).
2. Dismantle any screed extensions (refer to the documentation for the screed).
Reduce the Vario extensions to the minimum width on Variomatic screeds
(Chapter 3 “Variomatic Screed, Extend and Retract”, Page 3-39).
3. Dismantle any other components which may be an obstacle or accident prone
during transport. For example, the auger extensions or direction indicator.
4. Raise and secure the screed in the transport locking device (refer to Chapter 3
“Screed Transport Lock”, Page 3-36).
5. raise the augers to the uppermost position (Chapter 3 “Auger Height
Adjustment”, Page 3-42).

Chapter 3 OPERATION
6. Move the engine throttle lever (A38) to the maximum speed.

7. Move the toggle switch (A13) to the transport speed stage (H).
8. Turn the steering potentiometer (A26) to the centre zero position.
9. Turn the speed potentiometer (A9) to the required travelling speed. Govern the
speed with the engine throttle lever.
10. Ensure no persons are in the direction of travel and sound the warning horn to
warn person in the danger zone.
11. As soon as you move the drive lever (A25), the spring loaded brake will be
released and the paver will start moving.
• Push the drive lever (A25) forwards and the paver will travel forward.
• Pull the drive lever backwards and the paver will travel in reverse.
• Return the drive lever to the centre neutral position to stop the paver.
12. Use the steering potentiometer (A26) to steer the paver.

OPERATION Chapter 3
TURNING ON-THE-SPOT)
Illustration 17
The function of turning on the spot will not operate if the electronic control for the travel drive
is faulty.
1. Stop the paver by returning the drive lever (A25) to the neutral zero position.
2. Move the toggle switch (A13) to the low paving speed stage (L).
4. Move the toggle switch "Turning on the spot" (A14) to position "1" and keep it
in this position.
5. Ensure nobody is in the paver's slewing range and sound the warning horn to
warn persons in the danger zone.
6. The paver will turn on the spot as soon as you turn the steering potentiometer
(A26):
• Turn the paver to the right: Rotate the steering potentiometer (A26) to the right
• Turn the paver to the left: Rotate the steering potentiometer (A26) to the left
• The more you rotate the potentiometer, the faster the paver will turn.
7. As soon as the paver has reached the required direction, return the steering
potentiometer (A26) to the centre zero position and release the toggle switch
"Turning on the spot" (A14).

Chapter 3 OPERATION
OPERATING THE PAVER IN AUXILIARY CONTROL (EMERGENCY CONTROL)

The electronic control for the travel drive will automatically switch to auxiliary control if a failure
occurs on one of the rotary sensors. A faulty sensor will be indicated by the control lamp for
the rotary sensor flashing. The system must be switched to auxiliary control if the electronic
control fails. To do this, open the rear door on the control column and move the switch (1) up-
wards to the auxiliary control position.
Illustration 18
Operating the paver in auxiliary control will be the same as in normal control, i.e. use the drive
lever (A25, 27Page), the speed potentiometer (A9, 27Page) and the steering potentiometer
(A26, 27Page) refer to ”Driving the Paver on Roads and Job-sites”, page 3-25.
Remarks: When operating the paver in the auxiliary control mode,

acceleration and braking will react a lot slower. Therefore, we
recommend to start and stop the paver by rotating the speed
potentiometer (A9, 27Page).
Starting the paver
1. Rotate the speed potentiometer (A9, 27Page) to the centre zero position.
2. Move the drive lever (A25, 27Page) to the required direction of travel.
3. Rotate the speed potentiometer (A9, 27Page) to accelerate the paver to the
required speed.
Stopping the paver
Remarks: Only stop the paver by pressing the emergency STOP button
(A11, 27Page) in cases of danger.
1. Rotate the speed potentiometer (A9, 27Page) to the centre zero position.
2. Return the drive lever (A25, 27Page) to the centre zero position.

OPERATION Chapter 3
PREPARING THE PAVER FOR OPERATION
! CAUTION
Cordon off the working area. When preparing the paver for operation,
only those persons involved with setting-up work may enter the working
area.
During operation, the paver's engine may only be started when it is

absolutely necessary for paving work. A running engine is an increased
risk of accidents. Therefore, work with exceptional caution.
NOTICE
Drive the paver to its working position parallel to the lane to be paved.
Refuel beforehand if necessary.

Chapter 3 OPERATION
REFUELLING THE PAVER

The fuel tank is located on the RH side of the paver. The fuel level is shown on the fuel level
indicator (A2, 27Page) on the control panel. The exact level can only be shown when the ma-
chine is standing on level ground.
! CAUTION
Fire risk: Do not smoke and avoid sparks and naked flames when
refuelling.
• Switch off the engine and ensure a good ventilation when refuelling.
• Wear protective clothing to protect your eyes, hands and respiratory passages.
• Do not spill any fuel when refuelling the machine. Immediately remove any fuel
spilled.
NOTICE
Never let the fuel tank run dry, otherwise the entire fuel system must be
dearated. Refuel the paver at the end of a working shift to prevent
condensation forming in the tank.

OPERATION Chapter 3
Illustration 19
1. Switch off the paver's engine.

2. Unlock and remove the filler cap (1) by turning it slowly anti-clockwise.
3. Remove the strainer (2) from the filler neck and clean it with Diesel fuel if
required. Correctly dispose of any used Diesel fuel. Do not let it escape into the
environment.
4. Carefully refuel with a quality of Diesel fuel specified in the list of "Fuel, Oils, &
Lubricants".
5. Close and lock the filler cap (1) by turning it clockwise.

Chapter 3 OPERATION
LUBRICATING THE PAVER

The paver is equipped with a central lubrication system located inside the RH side door. Dur-
ing paver operation, the following assemblies will be automatically lubricated at specified in-
tervals (i.e. for 16 minutes every two hours):
• Basic Augers
• Conveyors including the conveyor drive shaft and the conveyor idler shaft.
• Auger bearing arms.
Ensure the grease container is adequately filled with grease when putting the paver into oper-
ation. Before and after paving work, activate the rapid lubrication function by pressing the illu-
minating button switch H10 for the "Rapid Lubrication".
! CAUTION
Observe the following:
• Only operate the central lubrication with the pressure relief valve installed in the
system and ensure the valve is functional. If grease appears out of the pressure relief
valve, at least one lubrication circuit has a blockage and the respective lubrication
point will no longer be supplied with grease. Immediately remove the blockage.
• The central lubrication system functions automatically. Nevertheless, check at
regular intervals and ensure that lubricant emerges from the grease points.
• The grease container must never run empty otherwise the pump must be deareated.

OPERATION Chapter 3
Illustration 20
1. Check the MIN and MAX level marks on the grease container to ensure there
is sufficient lubricant in the system. If the level is too low:
• Switch off the paver's engine.

• Fill the grease gun (4) with grease according to the list of "Fuel, Oils &
Lubricants".
• Remove the threaded cap (2).
• Insert the grease gun (4) on the connection and pump grease into the container
until the MAX level mark has been reached.
• Replace the threaded cap (2) on the connection.
2. Start the engine and press the illuminating button switch for a rapid lubrication
(A10, 27Page) on the control panel. The control lamp illuminates during the
lubrication process.
NOTICE
Carry out point 2 before and after paving work.

Chapter 3 OPERATION
FRONT CROSS BEAM

The front cross beam (3) is attached to the front of the basic frame by a bolt (4). Buffer rollers
(5) are fitted to the front cross beam for pushing the truck when it charges the hopper. The
oscillating suspension of the front cross beam is designed to take up steering movements be-
tween the paver and the dump truck during the charging process.
Illustration 21
1. Whenever necessary, clean off any bitumen and dirt which has accumulated
on the truck buffer rollers (5).
• Scrape or brush off solid material

• Remove bituminous materials with the emulsion spraying system
• Use water to remove any non-bituminous material

OPERATION Chapter 3
ROAD SCRAPERS, RAISING AND LOWERING

Road scrapers (2) are mounted in front of the LH and RH crawler tracks. The road scrapers
are lowered for paving work to clear away any obstacles such as paving material spilled out of
the hopper from the path of the crawler tracks.
! WARNING
The road scrapers must be raised for transporting and loading the paver.
Otherwise they will be damaged.
Illustration 22he
Lowering the Road Scrapers
1. Hold the road scraper (2) in the raised position.

2. Turn the spring loaded locking bolt (3) through approx. 180 degrees.
3. Slowly lower the scraper (2).
Raising the Road Scrapers
1. Raise the lowered road scraper (2) by hand.

2. As soon as the hole coincides with the spring loaded locking bolt (3), turn it
through approx. 180 degrees.
Adjusting the Road Scrapers

The road scrapers (2) should touch the ground when the screed is in the raised position. By
raising the screed, the paver's centre of gravity will be transferred to the rear of the machine.
1. Adjust the height of the road scraper (2) with the adjusting screw (4) as
previously described.

Chapter 3 OPERATION
HOPPER WINGS, OPEN AND CLOSE
! WARNING
Close and lock both hopper wings before transporting the paver.
Otherwise there will be an increased risk of danger because the hopper
wings protrude beyond the basic width of the paver.
Illustration 23
The hopper (1) is fitted with two wings. The hopper serves as a bunker for the paving material
during paving work. The hopper wings can be closed to completely empty the hopper during
paving work. The hopper wings must always be opened for the dump truck to charge the hop-
per.
Hopper Wings, Open and Close
1. Use the levers (2) to release both hopper wings. Both locking hooks (3) must
be completely free.
2. Ensure there are no persons or obstacles in the danger zone and sound the
warning horn to warn other persons of a potential danger.
3. Use the toggle switch A22 on the control panel to open and close the hopper
wings.
4. Use the levers (2) to lock the hopper wings in the closed position. The LH and
RH locking hooks (3) must safely lock into position.
SCREED TRANSPORT LOCK

The screed transport lock is a manually operated mechanical locking device. The towing arms
(2) rest in the hooks (1) and secures the screed against lowering during transport. This will re-
lieve the load from the screed transport cylinders.

OPERATION Chapter 3
! WARNING
The screed must be raised and secured in the transport lock before
loading and transporting the paver. Otherwise it may collide with the
ground and be damaged.
Never alter the position of the tow points if the screed is raised and
secured in the transport lock,i.e. do not actuate the toggle switches A16
and A37 (27Page). Otherwise the transport locking device will be
damaged.
Illustration 24

Chapter 3 OPERATION
Raising and Securing the Screed in the Transport Lock
1. Move the toggle switch A29 for the "screed floating mode" to the LH "O"
position. (manual control).
3. Move the toggle switch A31 „screed raise / lower“ to the raise position until the
towing arms have reached their highest position.
4. Move the levers (3) to the lower position in the slotted gate on both sides of the
paver. The spring loaded locking hooks (1) will grip underneath the towing arms
(2).
5. Move the toggle switch A31 „screed raise / lower“ to the lowering position until
the screed transport cylinders are relieved of load.
Releasing and Lowering the Screed from the Transport Lock
1. Move the toggle switch A29 for the "screed floating mode" to the LH "O"
position. (manual control).
3. Move the toggle switch A31 „screed raise / lower“ to the raise position until the
towing arms have reached their highest position.
4. Move the levers (3) to the upper position in the slotted gate on both sides of
the paver. The spring loaded locking hooks (1) will retract and release the
screed.
5. Move the toggle switch A31 „screed raise / lower“ to the lowering position until
the screed rests on the ground.

OPERATION Chapter 3
VARIOMATIC SCREED, EXTEND AND RETRACT
! WARNING
When extending or retracting the Variomatic screed, the operator must
keep the respective side well within his vision so that he can immediately
stop the screed if there is a danger to persons in the vicinity.
The screed must be retracted to the basic width before transporting the
paver. Otherwise there will be an increased risk of danger because the
extended screed will be wider than the basic width.
Raise and secure the screed in the transport lock for transport and when
working on the screed.
Illustration 25
2. Press the button switch B4 or B5 and keep it pressed to extend or retract the
screed. Button switches B4 and B5 are located on both LH and RH external
control panels.

Chapter 3 OPERATION
SCREED TENSIONING DEVICE, ASSEMBLING AND DISMANTLING

The screed tensioning device will improve the paving behaviour especially on Variomatic
screeds at large widths. It has a permanent positive influence on the screed's floating behav-
iour and ensures a positive angle of attack. A support plate (A) prevents the tensioning cylin-
ders on the screed tensioning device from dropping downwards.
We recommend the application of the screed tensioning device on Variomatic screeds at pav-
ing 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 metres.
! WARNING
Before operating the screed tensioning device, ensure there are no
persons in the danger zone or even working on the device itself.
Ensure the wire rope does not wind around the auger extensions when
retracting the Variomatic screed.
Check the clamps (8) on the wire rope for tightness before using the
screed tensioning device.

OPERATION Chapter 3
Illustration 26 (example shown on a wheeled paver)
1. Extend the screed to its maximum paving width (refer to ”Variomatic Screed,
Extend and Retract”, page 3-39).
2. Fit the tensioning cylinder (3) into the swivel bracket (4).
3. Connect the hydraulic hoses (5) to the tensioning cylinder.
4. To extend the ram on the hydraulic cylinder, swap the hoses (5) to opposite
connections. Thereafter, return the hoses to the correct connections.
5. Use the shackle (6) to connect the wire rope (1) to the eye on the tensioning
cylinder (3).
6. Bolt the connecting plate (2) to the end plate on the Variomatic screed.
7. 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 cylinder are
both fully extended.
8. Move the toggle switch for the screed tensioning device to the ON position.
Both tensioning 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.
Remarks: To dismantle the screed tensioning device, use the quick

action couplings (10) to swap the hydraulic hoses (5) to opposite
connections. The ram on the hydraulic cylinder can now be retracted.
Thereafter, return the hoses to the correct connections. Thereafter,
proceed in the reverse sequence described above.

Chapter 3 OPERATION
SCREED SPACER BLOCKS (OPTION)

Screed spacer blocks are used for paving thicker mats to increase the width of the auger chan-
nel.
! WARNING
There is an increased risk of accidents when fitting the screed spacer
blocks because the paver must be moved during this work. Therefore,
work with exceptional caution.
Illustration 27
Fitting the Screed Spacer Blocks
1. Completely lower the screed to the ground.

2. Remove the 4 standard bolts (3) from the flanges (2).
3. Drive the paver forward by approx. 60 mm.
4. Insert the 2 spacer blocks between the flanges (2).
5. Insert and tighten the 4 longer bolts (3).
Removing the Screed Spacer Blocks
1. Completely lower the screed to the ground.

2. Remove the 4 long screws (3) from the flanges (2).
3. Drive the paver forward by approx. 10 mm.
4. Remove the spacer blocks from between the flanges (2).
5. Drive the paver backwards by approx. 70 mm.
6. Insert and tighten the 4 standard screws (3).
AUGER HEIGHT ADJUSTMENT

The augers () are mounted on the paver's rear wall. The augers laterally distribute the paving

OPERATION Chapter 3
material in the auger channel. The augers are controlled by rubberised level switches, option-
ally by ultrasonic sensors, mounted on the auger outer bearings or LH and RH screed end
plates. The installation of the optional ultrasonic sensors is described in the operating manual
for the screed.
When paving thinner mats, the head of material in the auger channel can be reduced with the
augers in a lower position. This will reduce the shearing resistance on the screed and improve
traction.
! WARNING
Wear gloves when working on the augers. The surfaces of the mix
conveyor system have sharp edges and may still be hot shortly after
paving work.
Ensure the augers do not collide with the ground when driving the paver
or loading it on a transport vehicle; this would lead to damage on the
augers. Raise the augers if necessary.

Chapter 3 OPERATION
Adjusting the Height of the Basic Augers
Remarks: The following instructions apply to augers with mechanical

height adjustment (illustration refers) and augers with hydraulic height
adjustment. Both versions are available with centre auger drive
(illustration refers) and outer auger drives.
Illustration 28:
1. If installed, disconnect the auger extensions with outer bearings from the basic
auger or use suitable lifting tackle to adjust their height (refer to „Adjusting the
Height of Auger Extensions with Outer Bearings“).
Remarks: The augers can be adjusted to any height within the adjusting
range if only the basic augers or the basic augers with auger extensions
but without auger outer bearings are used. In this case, the locating bolt
(1) will not be required and should be screwed into the adjacent hole for
safe keeping.
If the paver is fitted with auger outer bearings, the augers may only be
adjusted to the positions of -30 mm, 0 mm or +30 mm because the outer
bearing will only permit these adjustments. In this case, the locating bolt
(1) must be used.
2. If fitted, unscrew and remove the locating bolt (1) from the paver's rear wall.
3. To set the mechanical height adjustment, turn the barrel nut on the turnbuckle
(1) to raise or lower the augers by up to 30 mm from the zero position (the holes
for the locating bolt are positioned at -30 mm, 0 mm ,+30 mm).
To set the hydraulic height adjustment, raise or lower the augers by pressing
the switch (3) located on the LH seat console in the required direction.
4. If necessary (Remarks refer), secure the setting with the locating bolt (1).

OPERATION Chapter 3
Adjusting the Height of the Augers with Outer Bearings
Illustration 29: Auger extensions with outer bearings
1. Slightly raise the outer end of the auger extension (5) with a suitable lifting
device. Do not exert any pressure on the bearing holder.
2. Loosen and remove the screws (4) from the bearing arm (3).
3. Raise or lower the auger extension with the lifting device until it has reached the
same level as the basic augers.
4. Replace the bearing arm (3) using the screws (4) and tighten the screws.
5. Remove the lifting device.
6. Repeat this procedure on the other auger side.

Chapter 3 OPERATION
FITTING AUGER EXTENSIONS
! WARNING
Switch off the Diesel engine before fitting any auger extensions.
Worn auger flights have sharp edges. Wear working gloves to protect
your hands.
Auger flights must be fitted to clean surfaces without free play. Protect
the ends of the auger shafts against wear by fitting the protective end
caps.
Fit the protective guards above the auger extensions. Protective guards
are supplied for the auger channel on manual screeds and for the height
adjustable channel plates on Variomatic screeds.
Auger extensions must be dismantled for transport. Otherwise there will

be an increased risk of danger because the auger extensions protrude
beyond the basic width of the paver.

OPERATION Chapter 3
Illustration 30
The configuration of the auger extensions and protective guards for each particular paving
width is contained in the screed assembly plan.
1. Remove the protective end cap and screw from the basic auger shaft.
2. Connect the auger channel plate (4) to the paver's frame with the screws (2).
3. Connect the horizontal brace (3) between the channel plate (4) and the bracket
on the paver. Use the front connecting bolt (1) with safety clip on the paver and
the connecting bolt (5) on the channel plate to secure the horizontal brace.
4. use the turnbuckle (1) on the horizontal brace (3) to align the auger channel
plate with the paver's rear wall.
5. 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).
6. Adjust the turnbuckle on the vertical brace (7) so that the auger channel plate
is at an angle of 90 degrees to the paver's side wall.
7. Push the auger extensions (20) onto the basic auger. Ensure the pitch on the
basic auger and auger extension is the same.
8. Connect both coupling pieces (11) with the screw (10) and fit a 140° auger flight
(9) if required.
9. Fit the bearing arm (18) with the screws (19) to the support plate (17). The
auger extension must be adjusted to the same height as the basic auger.

Chapter 3 OPERATION
10. 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 a M20 x 140 screw to improve the distribution
of the paving material.
11. Fit the hinged end plate (14) to the bracket (13) using the screws (12) as
illustrated.
12. Finally ensure that all protective guards (21) have been fitted and that they are
not damaged.
13. Stretch a piece of string across the entire width of the augers and check the
horizontal and vertical alignment of the auger extensions (20) with the basic
augers.
Remarks: With the exception of the auger flight pitch, the assembly of the
left- and right-hand augers is the same. The assembly of the adjustable
channel plate is the same for auger extensions with or without auger
outer bearings. The length of the adjustable channel plate and the auger
extensions vary according to the particular paving width.
Remarks: The adjustable channel plates achieve a more uniform

distribution of material in front of the screed. The pitch of the 140° auger
flight must be the same as the pitch on the basic auger. If mix segregation
occurs in the area of the auger outer bearing, it can be rectified by
swapping the flights.
Remarks: Fit a right-hand auger flight to the left-hand side and vice versa.
The same applies to the 140° auger flight at the end of the auger shaft.

OPERATION Chapter 3
AUGER CONTROL, ADJUSTING
! WARNING
Wear gloves when working on the augers. The surfaces of the mix
conveyor system have sharp edges and may still be hot shortly after
paving work.
Illustration 31
The auger control consists of two rubberized level switches. The level switches are mounted
at different positions depending on the paving width.
Small paving widths: Mount the rubberized level switches at position (1) as illustrated.
Large paving widths: Mount the rubberized level switches at position (2) as illustrated.
Remarks: The flat side of the rubberized level switches must always face
towards the paving material. Immediately renew faulty components with
genuine parts.

Chapter 3 OPERATION
ADJUSTING THE CONVEYOR CONTROL (PADDLE TYPE CONTROL

SWITCHES)
The paddle type switches (1) are located on either side of the auger drive case on the rear of
the paver. They control the flow of material during paving work. The conveyor control is cor-
rectly adjusted when the augers are submerged by approx. 2/3 in the paving material.
! WARNING
Switch off the engine and remove the ignition key before adjusting the
paddle type conveyor control switches. Wear gloves to adjust the paddle
type control switches.
Illustration 32
Too much material in the auger channel
1. Push the paddle type control switches (1) towards the paver's rear wall.
Not enough material in the auger channel
1. Pull the paddle type control switches (1) away from the paver's rear wall.

OPERATION Chapter 3
DIRECTION INDICATOR, SETTING UP

The direction indicator is installed in position A at the front of the basic frame (1) below the
cross beam (3). The direction indicator will assist you in steering the paver during paving work.
You can accurately steer the paver by guiding the indicator chain along a reference surface
such as a tensioned wire.
! WARNING
The direction indicator protrudes beyond the basic width of the paver
during paving work. Observe the extended width when driving the paver.
Illustration 33
1. Position the paver with the screed in the required width parallel to the reference
wire on the mat to be paved.
2. Loosen the clamp between the outrigger (6) and the indicator tube (7). Pull out
the indicator tube (7) to the required width.
3. Then retighten the clamp.
4. Loosen the fastening screw (11) and insert the angular tube (8) into the
indicator tube (7). Set the height of the angular tube (8) so that the two chains
(9) dangle either side of the reference wire.
5. Now tighten up the fastening screw (11). The clamps (10) holding the chains
(9) on the angular tube (8) can be repositioned on the tube as required.
6. Set the angular tube (8) so that it points outwards and to the front of the paver.
The angle between the indicator tube (7) and the angular tube (8) should be
approx. 105 degrees. If you work with only one chain (9), then this chain must
continuously dangle along the reference wire between the paver and the wire
itself.
ELECTRONIC LEVELLING SYSTEM

Instructions for setting up and operating the levelling system are contained in the documenta-
tion for your particular system.

Chapter 3 OPERATION
PAVING
SETTING THE OPERATING MODE AUTOMATIC
Illustration 34
We recommend the "Automatic" operating mode for paving work.
1. Move the toggle switches on the control panel to the following positions to set
up the "Automatic" mode:
• Toggle switch „Vibration“ (A7) to „AUTO“

• Toggle switch „Tamper“ (A8) to „AUTO“
• Toggle switch „LH Conveyor“ (A34) to „AUTO“
• Toggle switch „RH Conveyor“ (A19) to „AUTO“
• Toggle switch „LH Auger“ (A33) to „AUTO“
• Toggle switch „RH Auger“ (A18) to „AUTO“
• Toggle switch „RH Auger mode“ (A32) to „PROP“
• Toggle switch „LH Auger mode“(A17) to „PROP“

OPERATION Chapter 3
MAT THICKNESS, ADJUSTING

The mat thickness is set on the tow points.
! WARNING
The LH and RH screed towing arms must have almost the same setting.
The difference in the mat thickness must not exceed 10 cm. Otherwise the
screed will be distorted and damaged.
Illustration 35
When paving, the tow points must not ride against the upper or lower limit stops. Otherwise,
the hydraulic circuits for hopper open/close and screed raise/lower would no longer function.
If the tow points ride against the limit stops during paving work, the position of the screed tow-
ing arms must be altered relative to the paving screed so that the tow points have adequate
space to move between the limit stops. Further information is contained in the operating man-
ual for the screed.
1. Ensure the toggle switch for the "levelling system" (A35) is not switched to
position „1“; i.e. position „MAN“ or position „AUTO“.
2. The tow points on both towing arms are adjusted using the toggle switch (A16)
"RH tow point" and (A37) "LH tow point".
• Increasing the mat thickness: Move the toggle switches (A16 and A37) for the RH
and LH tow points upwards in the direction of the arrow until the required mat
thickness is reached.
• Reducing the mat thickness: Move the toggle switches (A16 and A37) for the RH
and LH tow points downwards in the direction of the arrow until the required mat
thickness is reached.
Remarks: Alternatively, the tow points can be adjusted on the external

control panel using the button switch for increase mat thickness (B1,
220Page) and for reduce mat thickness (B2, 220Page).

Chapter 3 OPERATION
SCREED FLOATING MODE

The correct screed floating mode is an important prerequisite for paving a perfect mat.
! WARNING
To avoid accidents, completely lower the screed before switching to the
floating mode.
Illustration 36
1. Place square timbers or paving material underneath the screed. This will set
the screed to the required mat thickness.Add the degree of mix slump caused
by rolling.
2. Move the toggle switch (A29) "screed floating mode" to the "O" position.
3. Move the toggle switch (A31) "screed raise/lower" downwards to lower the
screed onto the timbers.
4. Move the toggle switch (A29) "screed floating mode" to the position "1". The
screed is now in the floating mode.
5. Ensure the control lamp (A30) "screed floating mode" illuminates. If this is not
the case, the screed is not fully lowered and is in the hydraulically blocked
position. An uneven mat would result if the machine paved with the screed in
this position. Therefore, manually lower the screed further downwards.

OPERATION Chapter 3
NOTICE
We advise against starting paving work with a hydraulically blocked
screed and then switching to the floating mode after sufficient material is
forced underneath the screed. Normally, the screed would then not float.

Chapter 3 OPERATION
SCREED HEATING, ON / OFF
! DANGER
There is a danger of explosions caused by escaping gas. Keep all sparks
and naked flames far away from the gas heating components. Ensure
there is adequate ventilation. If a gas leakage occurs, immediately close
the valves on the gas bottles (turn the valve clockwise because it has a
left-hand thread).
The gas bottles for the screed heating must be safely secured against
falling over and be protected from the sun at ambient temperatures above
20° C (fit the gas bottle canopies).
Paving screeds can be heated by propane gas or Diesel fuel (only for
Variomatic screeds) heating systems.
Operating instructions for the propane gas or Diesel fuel heating system
can be taken from the operating manual for your particular paving screed.
There is a separate operating manual for the temperature controlled gas
blower heating system (Thermo-Control).
Strictly observe all locally prevailing directives and laws for operating the
heating system on your paving screed.
Some of the connections on the propane gas heating system have left-
handed threads. These can be recognised by a groove in all six surfaces
on the union nuts.
At the end of paving work, close the valves on the gas bottles, the
distributor and on the gas burners.
Before transporting the paver, close the valves on the gas bottles,
remove the gas hose with pressure reducer and fit the protective caps on
the gas bottles.

OPERATION Chapter 3
PAVING IN THE AUTOMATIC MODE
! WARNING
Depending on the ambient temperature, the hydraulic drives must warm
up for 2 to 5 minutes before starting paving work.
Govern the engine speed with the throttle lever (A38).
Before paving, ensure all protective guards and devices are correctly
installed and fully functional on the paver and screed.
Illustration 37
1. Move the engine throttle lever (A38) to the maximum speed.

2. Move the toggle switch (A13) to the low paving speed stage (L).
4. Turn the speed potentiometer (A9) to the required travelling speed.
Remarks: Altering the speed during paving work will alter the compaction
of the paving material and consequently the mat thickness. The speed
selected depends upon the paving width, the mat thickness and the kind
of paving material.
5. Ensure there are no persons in the danger zone around the paver.

Chapter 3 OPERATION
6. As soon as you move the drive lever (A25), the spring loaded brake will be
released and the paver will start moving.
• Push the drive lever (A25) forwards and the paver will travel forward.
• Return the drive lever to the centre neutral position to stop the paver.
7. Use the steering potentiometer (A26) to steer the paver.
PAVING MATERIAL PRONE TO SEGREGATION

Experience has shown that material in the area of the hopper wings has a significantly higher
portion of coarse grains. This segregated material should not be paved on its own because
areas of coarse grains would occur in the mat. Close the hopper wings and allow the segre-
gated material to flow onto the conveyors just before a new truck load of paving material is
dumped in the hopper. When doing this, the conveyors remain switched off until the hopper
has been filled with fresh paving material. The fresh paving material together with the segre-
gated material can now be conveyed to the augers. In this way, a mix segregation can be
avoided.
The conveyors should not run empty when changing dump trucks; forin fact, a layer of material
should remain in the hopper.
If possible, the head of material in the auger channel should have a uniform height across the
entire width of the screed. Depending on the thickness to be paved, this is achieved by lower-
ing the augers and removing an auger flight from those areas where there is not enough ma-
terial. Under certain conditions and especially at the outer screed areas, every second flight
must be removed. In this case we recommend that every second remaining flight should be
mounted offset by 180° on the auger shaft; this will give a uniform load on the auger shaft.
The conveyor and augers must be operated in the automatic mode. The sensors and control
switches must be so adjusted to reach a uniform head of material and the augers are only sub-
ject to minor speed alterations.
Run the tampers and vibrators at maximum speed when paving base courses. When paving
wearing courses, slightly reduce the tamper speed to prevent the screed loosing its floating
behaviour on account of a too high compaction.
If the previously mentioned measures do not prevent a concentration of coarse grain in front
of the augers and which reaches to the top of the mat being paved, the rear wall of the basic
machine in the area of the auger outer bearings must be extended downwards by fitting steel
plates or hard rubber sheeting to avoid the coarse grains rolling to the front. If necessary, these
steel plates or hard rubber sheeting must be fitted across the entire width of the screed (these
parts do not belong to the paver's standard range of supply).
Even at higher ambient temperatures, the screed must be permanently heated if material with
a temperature of 150° C and less is being paved. However, try to have the paving material
delivered with a mix temperature of 160 - 170° C.
If mix segregation occurs as an open surface structure in the middle area of the screed when
paving thicker mats, replace the first auger helical on one side with a helical with an opposite
pitch. This will force more paving material underneath the auger drive case and rectify the mix
segregation.
MAT THICKNESS IS NOT CORRECT

The screed's angle of attack must be altered by turning the rear turnbuckles if a significant dif-

OPERATION Chapter 3
ference occurs between the mat thickness set on the paver (value on the tow point mat thick-
ness scales) and the actual thickness of the mat being paved. The turnbuckles are set to a
value of "0" in the factory and increasing this value will achieve a thicker mat.
We recommend that the rear turnbuckles are not adjusted for paving mat thicknesses up to
approx. 10 cm. This means, that the screed's angle of attack will be adjusted by the tow points
to the mat thickness.
Rule of thumb: Value on the tow point thickness scales = 1.5 x the mat thickness.
Further instructions for adjusting the screed are contained in the screed's operating manual.
TOW POINT SINKS DOWN DURING PAVING WORK

Ball cocks are installed on the hose connections on the piston rod side of the levelling cylinders
and with these ball cocks, the cylinders can be blocked against sinking downwards. The ball
cock must be closed if the automatically operated double check valve leaks and allows the
screed to sink downwards at the tow points when paving. The ball cocks must remain open
when paving with an automatic levelling system to control the mat thickness.
CONVEYING THE PAVING MIX TO ONE SIDE

This section describes how to convey a uniform head of material to both sides of the screed
just before finishing paving work even though the hopper only has material on one side. Like-
wise, additional material requirements on one side caused by changes in the cross section
profile can be compensated by reversing one of the augers.
1. Conveying the paving material with both augers:
• to the LH screed side: Move the toggle switch A21 "auger reverse rotation" to the left
(27Page).
• to the RH screed side: Move the toggle switch A21 "auger reverse rotation" to the
right (27Page).
• to switch off: Move the toggle switch A21 "auger reverse rotation" to the centre
position (27Page).

Chapter 3 OPERATION
PAVING MATERIAL NOT CONVEYED FAST ENOUGH

The auger can be overmodulated if not enough paving material is being conveyed. The auger
will then rotate at maximum speed. For this function, the button B7 for "STOP material flow"
must be pulled upwards (27Page).
1. Rotating the auger at maximum speed:
• LH Auger: Keep the button switch B3 pressed on the LH external control panel to
overmodulate the auger (27Page).
• RH Auger: Keep the button switch B3 pressed on the RH external control panel to
overmodulate the auger (27Page).
SETTING THE PRESSURE ON THE SCREED ASSIST

If required, a variable pressure between 10 and 50 bar can be applied to the screed transport
cylinders.
This pressure counteracts the weight of the screed and prevents it sinking into paving material
with a low bearing capacity. This option does not effect the screed's floating behaviour; the
screed will bear down on the material with a reduced load.
Illustration 38
The control valve is located inside the LH side door on the paver's rear wall. The pressure is
adjusted as follows (Pos. 1 refers):
• Loosen the lock nut, 24 across flats

• Turn the Allen screw:
Clockwise to increase the pressure
Anti-clockwise to reduce the pressure
• Thereafter, tighten the lock nut.
Check the pressure on the test connection (2).

OPERATION Chapter 3
DAILY PROCEDURE AT THE END OF PAVING WORK

1. Refuel and clean the paver (Chapter 3 “Refuelling the Paver”, Page 3-30).
2. Drive the paver to the parking area. Ensure the paver does not cause an
obstruction.
3. Return the drive lever (A25, 27Page) to the centre zero position.
4. Lower the screed to the ground (Chapter 3 “Screed Transport Lock”, Page 3-
36).
5. With the conveyors and augers running, press the illuminated button switch
A10 „rapid lubrication“ (, 27Page).
6. Do not switch off the engine under full load; let it run without load at idling speed
for approx. 5 minutes to cool down.
7. Switch off the engine, remove the ignition key and lock the control panel.
8. Close the valves on the gas bottles and switch off the screed heating (Chapter
3 “Screed Heating, ON / OFF”, Page 3-56).
9. Switch off the power supply with the battery master switch and remove the red
plastic key (Chapter 3 “Switching the Power Supply ON and OFF”, Page 3-7).
10. Ensure all compartments and covers are closed and if possible, securely
locked.
11. Clean all parts and components which have been in contact with paving
material:
• Bituminous material: Use the optional spray cleaning system.

• Mineral aggregates, dry-lean concrete and similar materials: Use a water hose.
12. Clean the paver. In particular, remove all dirt, water or ice from the operator's
platform and in the vicinity of the external control panels which may pose a slip
hazard.
13. If the paver is not equipped with the optional central lubrication system, grease
the auger bearings, the auger seals as well as the drive shafts and idler shafts
for the conveyors (Chapter 4 “Grease Points”, Page 4-29).

Chapter 3 OPERATION
LOADING AND TRANSPORT
LOADING BY CRANE
! DANGER
Suspended loads are an increased hazard leading to serious injuries and
fatal accidents.
Only use hoisting and lashing chains and slings which comply with all
prevailing regulations.
Ensure that no persons are underneath a suspended machine.
Strictly observe the following instructions to avoid serious personal

injury and damage to the machine when loading and transporting the
paver:
• When choosing hoisting and lashing chains and slings, take the weight of the paver
(technical data refers) and the paving screed (refer to the screed's operating manual)
into consideration.
• Chains and slings must comply with all locally prevailing accident prevention
regulations and must have sufficient lifting capacity to take the weight of the machine.
• Only fasten hoisting and lashing slings and chains to the hoisting and lashing points
provided on the paver.
• Observe all locally prevailing laws, regulations and the traffic code when driving or
transporting the paver on public roads.
• Transport and loading work may only be carried out by qualified and authorized
personnel. Only experienced personnel should be assigned for attaching the crane
hooks to the machine and instructing the crane operator. The person giving the
instructions must be clearly seen by the crane operator.
• Raise the augers to their highest position before transporting the paver.Chapter 3
“Auger Height Adjustment”, Page 3-42
• Remove all loose objects from the paver before loading it by crane.

OPERATION Chapter 3
Illustration 39
Page 3-36).
2. Retract the operator's platform, seta console and sun roof and remove the
exhaust pipe (Chapter 3 “Setting up the Operator's Platform”, Page 3-8).
3. Remove the gas bottles from the paver (only applies to pavers fitted with the
optional gas heating).Chapter 2 “Screed Heating System (Option)”, Page 2-30
4. Dismantle any screed extensions to reach the specified transport width (refer
to the operating manual for your screed); raise and secure the screed in the
transport lock (Chapter 3 “Screed Transport Lock”, Page 3-36). Retract the
Variomatic screed to the basic width.
5. Remove all components from the paver which protrude beyond the basic width.
6. Switch off the engine, lock all compartments and switch off the power supply
with the battery master switch (Chapter 3 “Switching the Power Supply ON and
OFF”, Page 3-7).
7. Check all fluid levels so that they do not escape when the machine is tilted.
8. Remove all loose objects from the paver.
9. Lower the sun roof (Chapter 3 “Raising and Lowering the Sun Roof”, Page 3-9).
10. Use wheel chocks to secure the front and rear wheels of the transport vehicle.
11. Attach the crane slings to the hoisting points marked on the paver (illustration
refers).

Chapter 3 OPERATION
12. The load suspension point (Fz) must be brought to a position vertically above
the paver's centre of gravity (Fg).
• The paver's centre of gravity (Fg) depends upon the type of screed fitted to the
machine.
• Basically, the paver's centre of gravity is between the first and second track roller
in front of the crawler drive assembly.
13. Place dismantled screed extensions or similar heavy objects in the hopper to
balance the weight of the paver when hoisting. Ensure the items placed in the
hopper are safely secured against moving.
14. Cordon off the loading area and ensure no persons are in the danger zone.
15. Carefully hoist the paver with the crane and check the lashing points and
balance. Only hoist the paver onto the vehicle after checking that all crane
slings are correctly attached and the machine is not out of balance.
16. Position the paver on the vehicle so that it is exactly in the middle of the loading
bed.
17. Securely lash the machine as soon as it is on the loading vehicle. (refer to
”Lashing the Machine on the Vehicle”, page 3-66).

OPERATION Chapter 3
LOADING ON A VEHICLE WITH RAMPS
Page 3-36).
2. Retract the operator's platform, seat console and sun roof. Remove the exhaust
pipe (Chapter 3 “Setting up the Operator's Platform”, Page 3-8).
3. Remove the gas bottles from the paver (only applies to pavers fitted with the
optional gas heating).Chapter 2 “Screed Heating System (Option)”, Page 2-30
4. Dismantle any screed extensions to reach the specified transport width (refer
to the operating manual for your screed); raise and secure the screed in the
transport lock (Chapter 3 “Screed Transport Lock”, Page 3-36). Retract the
Variomatic screed to the basic width.
5. Remove all components from the paver which protrude beyond the basic width.
6. Check all fluid levels so that they do not escape when the machine is tilted.
7. Remove all loose objects from the paver.
8. Park the transport vehicle on firm and even ground and secure the front and
rear wheels with wheel chocks.
9. Keep the bed of the loading vehicle free from clay, oil, mud, ice and frost which
are a slip hazard.
10. Use suitable loading ramps. Ensure that the loading ramps have sufficient
bearing capacity, and low ramp angle (< 25%), the correct height and width and
a non-skid surface.
11. Drive the machine up the ramp in a straight line so that it does not slide or tilt
off the side of the ramp.
12. Position the paver on the vehicle or low loader so that it is exactly in the middle
of the loading bed.
13. Stop the engine and lock all compartments.
14. Securely lash the machine on the loading bed (refer to ”Lashing the Machine
on the Vehicle”, page 3-66).
15. Lower and secure the sun roof (Chapter 3 “Raising and Lowering the Sun
Roof”, Page 3-9).
16. Switch of the power supply with the battery master switch (Chapter 3 “Switching
the Power Supply ON and OFF”, Page 3-7).

Chapter 3 OPERATION
LASHING THE MACHINE ON THE VEHICLE
! DANGER
Only use hoisting and lashing chains and slings which comply with all
prevailing regulations.
Strictly observe the following instructions to avoid serious personal

injury and damage to the machine when loading and transporting the
paver:
• When choosing lashing chains and slings, take the weight of the paver (technical
data refers) and the paving screed (refer to the screed's operating manual) into
consideration.
• Chains and slings must comply with all locally prevailing accident prevention
regulations and must have sufficient strength to take the weight of the machine.
• Only fasten the lashing slings and chains to the lashing points provided on the paver.
• Observe all locally prevailing laws, regulations and the traffic code when driving or
transporting the paver on public roads.
Illustration 40
1. Release and lower the screed from the transport locking device (Chapter 3
“Screed Transport Lock”, Page 3-36). During transport, the screed must be
completely lowered and resting on the bed of the transport vehicle.
2. Finally, securely lash the machine on the bed of the loading vehicle using
suitable chains and slings in compliance with your locally prevailing regulations
and use wheel chocks if necessary. Attach the chains and slings to the lashing
points marked on the paver.

CHAPTER 4 - MAINTENANCE

Chapter 4 MAINTENANCE
MAINTENANCE
Only use genuine spare parts to uphold warranty claims and to achieve a reliable machine
operation as well as an optimum paving output.
IMPORTANT INSTRUCTIONS
! WARNING
Sudden and unexpected movements of the machine and moving parts
can cause injuries.
Before working on the paver, lower the screed (it must completely rest on
the ground) and switch off the engine.
Improper maintenance can lead to danger. Thoroughly read Chapter 1

“Safety”, Page 1-2 before performing any maintenance and repair work
on the paver.
• The procedures for starting and stopping the paver as well as the instructions for
maintenance work described in the operating manual must be strictly observed when
performing any work which affects the operation, configuration and adjustments on
the paver and its safety devices as well as maintenance, servicing and repair work.
• Ensure the area for maintenance work is adequately marked.
• The paver must be secured against unintentional starting as follows if it must be
completely shut down for maintenance and repair work:
— Remove the ignition key and the key for the battery master switch.
— Fasten a tag on the operator's platform with the text: „Maintenance work ! Do not
start the machine !
• Only carry out maintenance and repair work after the paver has been parked on firm
and level ground and safely secured against unintentional movements.
• Exercise extreme care to avoid accidents if lifting devices are attached to individual
parts and larger assembles for removing them from the machine. Only use lifting
devices which are in a perfect working condition and have the required lifting
capacity. Never work or stand below suspended loads.
• Always use the correct tools and workshop appliances for maintenance and repair
work on the machine.
• Always use suitable ladders or working platforms for assembly work on components
higher up on the machine. Never use components for climbing onto the machine.
• All grip bars, steps, handrails, platforms, decks and ladders must be kept free from
mud, dirt, snow and ice.
• Before carrying out any maintenance and repair work, clean the machine, especially
connections and threaded fastenings from oil, fuel and remnants of preservation
grease. Never use aggressive cleaning solvents. Always use non-fibrous cleaning

MAINTENANCE Chapter 4
cloths.
• Before cleaning the machine with water, steam jets (high pressure cleaners) or other
cleaning agents, close or seal with adhesive tape all doors, hatches and openings
which for safety or functional reasons must be protected against water, steam or
cleaning solvents. Exercise special care with electric motors and electronic
equipment.
• Ensure that temperature feelers do not come into contact with hot cleaning solvents
when cleaning the machine.
• Remove all covers and adhesive tape after cleaning the machine.
• After cleaning the machine, check all lines for fuel, grease and hydraulic fluid for
leakage, loose connections, chafing and damage. Immediately repair or renew all
faulty parts.
• Tighten all threaded connections previously loosened for maintenance and repair
work.
• After completion of maintenance and repair work, replace and check all safety
devices previously removed.
• Ensure that all consumables and spare parts have been correctly disposed of in
accordance with your locally prevailing environment regulations.
• Avoid carrying out maintenance, cleaning and inspection work when the engine is
running.
• Never refuel the machine if the engine is running, near naked flames and do not
smoke.
• Do not alter the engine adjustments. The details on the engine manufacturer's
identification plate must correspond to the engine adjustments.
• Always replace lost warning signs and symbols.The position and the part numbers
of the warning signs and symbols can be found in the spare parts list.
• By using genuine spare parts, you will maintain the operating safety and optimum
machine performance guaranteed in the warranty conditions.
• Switch off the power supply with the battery master switch before working on the
electrical system or carrying out any welding work on the machine (Chapter 3
“Switching the Power Supply ON and OFF”, Page 3-7).

• Ensure the battery cover is removed when connecting jump starter cables and
battery chargers to the battery (avoid an accumulation of battery gasses). Battery
gasses can be ignited to an explosion by sparks.
• The battery charger MUST be switched off when connecting it to the battery.
• Only use genuine fuses with the specified amperage. Immediately switch off the
paver if problems occur in the electrical system.
• Any work on the machine's electrical system and equipment may only be performed
by a trained assistant electrician or a similarly trained person whereby they are
supervised and controlled by a fully trained and qualified electrician. This work must
be carried out in accordance with your locally prevailing electro-technical regulations
and directives.
• If required by regulations, the power supply to the paver's sub-system on which
inspection, maintenance or repair work is to be carried out, must be interrupted.
• Before starting work, ensure the sub-system, is disconnected and at zero potential
and earthed or short circuited. Furthermore, all live parts and components must be
isolated.
• The paver's electrical equipment must be checked and examined at regular intervals.
Faulty parts such as loose connections or charred wiring must be immediately
renewed.
• Welding, torch cutting and grinding work may only be carried out on the paver after
express permission has been obtained because this work can cause explosions and
fires.
• Before commencing any welding, torch cutting or grinding work, the paver and its
surrounding area must be cleaned and free from all dust and inflammable materials
and the working area must be adequately ventilated (danger of explosions - check
all wiring and hoses for leakage and visual damage). Any damage found must be
immediately repaired. Escaped oil is a fire risk and health hazard.
• Hydraulic hoses must be regularly checked and immediately renewed if they are
found to be chafed, cracked, brittle, deformed or have visible bulges, leakages, loose
connections or any other damage which impairs their function or durability.
• Never carry out any work on the hydraulic lines when the engine is running and the
system is under pressure. Hydraulic fluid is still under pressure even though the
engine has been switched off.
• Before starting any repair work, all systems and the pressure lines to be removed
(hydraulic system, compressed air system) must be depressurised in accordance
with the instructions for the particular components.
• Never commence any work on hydraulic hoses and connections until the pressure
has been properly relieved from the system.

• Wait until the hydraulic fluid has cooled down before disconnecting any hydraulic
hoses. Hot hydraulic fluid will cause serious burns and scolding.
• Do not use your hand to check for leakage in the hydraulic system. Use a piece of
cardboard and wear protective gloves and goggles.
• Even a small amount of hydraulic fluid can cause serious injuries and fatal accidents.
Immediately remove hydraulic from your skin. Immediately go to a doctor if hydraulic
fluid gets into your eyes, you swallow or breath it.
• Hydraulic lines must be correctly routed and properly connected. Ensure the
hydraulic connections are not swapped with each other. The connections, length and
quality of the hydraulic lines must comply with all technical requirements.
• Strictly observe the product specific safety regulations when handling oil, grease and
other chemical substances.
• Exercise special care when handling hot materials (danger of burning and scolding).
BEFORE STARTING MAINTENANCE WORK

Ensure the following points are observed before starting maintenance work:
1. Park the paver on firm and even ground. Cordon off the working area.
2. Switch off the engine and let it cool down.
3. Switch off the power supply with the battery master switch (Chapter 3
“Switching the Power Supply ON and OFF”, Page 3-7).
Remarks: The power supply should not be switched off to check certain
faults.
4. After stopping the engine, wait until the hydraulic oil pressure has dropped
before starting maintenance work on the hydraulic system.
5. Before starting maintenance work, clean all threaded connections, caps and
plugs etc with a non-flammable and non-toxic cleaning solvent so that dirt
cannot penetrate the system during work.

HANDLING HAZARDOUS MATERIALS
1. Have suitable and lockable containers at hand for draining off fluids. Ensure no
fluids are spilled. Remove any spilled hazardous materials and dispose of them
in an environmentally manner.
2. Dispose of all used fluids, lubricants, filters and batteries etc in accordance with
your locally prevailing environment regulations.
WELDING WORK ON THE PAVER
Disconnect the following before welding on the paver:

• Electronic travel drive
• Levelling system
• Battery master switch
• All other electronic equipment
• Battery
• Alternator
Furthermore, the earth terminal on the welding appliance must be clamped in the immediate
vicinity of the part to be welded. The welding current must not pass through bearings.
Reconnect the above components in the opposite sequence on the completion of welding
work.
FIRST OIL CHANGE

Carry out the following maintenance work after running in a new machine for approx. 50
operating hours. Thereafter, carry out the regular maintenance intervals specified on the
following pages.
1. Change the engine oil and oil filters.

MAINTENANCE CHART
The maintenance chart contains the components which must be regularly serviced and their
maintenance intervals. All components listed under a maintenance interval should be regularly
serviced. These intervals are based on the average operating conditions and manufacturer's
recommendations. The maintenance intervals must be shortened if the machine is operated
under extremely difficult, dusty or humid conditions (more frequent maintenance is required).
In the following table, the maintenance intervals specified by the manufacturer may deviate
from those intervals specified by the engine manufacturer but must still be adhered to. When
performing the work for a maintenance interval, you must also perform the work for the previ-
ous intervals. For example, if you carry out a yearly maintenance, you must perform the work
for the yearly intervals and also for the half-yearly, quarterly, weekly and daily maintenance
intervals.
NOTICE
Please refer to the separate documentation for the maintenance work for
the screed and engine.
The maintenance work marked with an asterisk * must be carried out

together with the first service at 100 operating hours. Thereafter, the
specified maintenance intervals apply.
Table 5: Maintenance Chart
Further
Maintenance Work
Information
As required
Tighten threaded connections 410Page
Charge the battery 414Page
Clean the sieve in the fuel tank filler neck 330Page
Clean the filler neck sieve for the emulsion spraying system 226Page

Further
Maintenance Work
Information
EVERY 10 OPERATING HOURS (DAILY)
Clean the machine and visual check 410Page
Check the grease level for the central lubrication system 332Page
Grease the conveyor drive shaft 429Page
Grease the auger drive case seal and all auger bearings 429Page
Check the engine oil level and top up if necessary 411Page
Check the hydraulic oil level 436Page
Check the pump distributor gear 420Page
Check the travel drive transmissions 420Page
Functional test on the warning devices (horn, lights, controls and –
instruments etc)
EVERY 40 OPERATING HOURS (WEEKLY)

Grease all drive chains 428Page
EVERY 100 OPERATING HOURS

Check the oil level in the travel drive transmissions 433Page
Check the sag on the conveyor drive chains 421Page ff
Check the sag on the conveyor chains 421Page ff
Check the sag on the auger drive chains 421Page ff
Check the auger bearing protectors for wear –
Drain the water out of the auger drive case 421Page ff
Check the oil level in the pump distributor gear 434Page
Check the battery terminals 414Page
Drain the water from the preliminary fuel filter 421Page
Check the coolant level and top up if necessary 412Page

Clean the hydraulic oil cooler and radiator 419Page

Further
Maintenance Work
Information
Grease the slip guides and guide rollers on the towing arms 429Page ff
Grease idler bearing 429Page ff
Diesel engine - oil change * Engine handbook
Diesel engine - change the oil filter cartridge * Engine handbook
Diesel engine - tension the V-belt * Engine handbook
Change the hydraulic oil filter * 415Page

Change the fuel filter cartridge Engine handbook
Change the air filter cartridge Engine handbook
Check the bolts on the hydraulic cylinders for tight fitting and wear –
Check the cooling system for leakage –
Change the filter cartridges for the levelling cylinders and augers 416Page
Change the filter cartridge for the travel drive and tamper drive 417Page
Clean the vent filter on the hydraulic oil tank 418Page

Change the pump distributor gear oil * 434Page
Change the transmission gear oil * 433Page

Change the engine coolant Engine handbook
Change the hydraulic oil * 436Page
Change the vent filter on the hydraulic oil tank 418Page
* First service at 100 operating hours

MAINTENANCE WORK
! CAUTION
The engine must be switched off when carrying out the following
maintenance work.
MACHINE (GENERAL)
Cleaning the Machine

When cleaning the machine and machine components with a hose or high pressure cleaner,
water and other impurities can penetrate bearings, seals and other components in the system.
NOTICE
When using high pressure cleaners, ensure that water or steam does not
penetrate electrical components and control systems.
Do not use any aggressive cleaning solvents which may cause damage
to painted surfaces.
Let the engine run warm after washing the machine. This will allow the
engine components and electrical connections to dry quicker.
Lubricate all grease nipples after cleaning the machine.
Before Cleaning
1. Remove all paving material stuck to the machine.

After Cleaning:
1. Remove all material used to prevent water penetrating the machine.

2. Immediately lubricate all grease nipples.
3. Check all air intakes for deposits of dirt which may constrict the flow of air and
ensure a free and unobstructed air intake.
4. Check all fastenings on the air filter and repair any damage found.
5. Check all hoses for cracks, wear and damage and renew them if necessary.
Tighten threaded connections
1. Correctly tighten all loose nuts and threaded connections found during daily
maintenance. (refer to ”Torques for threaded connections”, page 8-2.)
2. Renew any loose self-locking nuts if necessary.

DIESEL ENGINE
NOTICE
Instructions for upkeep and maintenance procedures for the Diesel
engine as well as details of the required consumables are included in the
appended engine manufacturer's handbook.
Check the engine oil level
! CAUTION
Wrong oil level. The wrong oil level will damage the engine. Switch off the
engine and weight for about 10 minutes for the oil to settle in the sump.
Illustration 6:
1. Remove the oil dip stick (1).

2. Wipe the dip stick (1) dry with a non-fibrous cloth.
3. Replace the dip stick (1) into the engine.
4. Remove the oil dip stick (1). Check the oil level on the dip stick.
• If the oil level is between „max“ and „min“: the level is OK.
• If the level is above „max“: Drain off oil to the correct level. (refer to ”Oil Change,
Diesel Engine”, page 4-38)
• If the level is below „min“: Add oil through the filler cap (2) to the correct level.
5. Replace the dip stick into the engine.

Fuel filter - draining off the water
Illustration 7:
1. Open the cock (1) to drain off the condensed water.

2. Close the cock (1).

ELECTRICAL SYSTEM
! WARNING
Batteries contain acid which can lead to injuries.
Battery vapour can ignite and explode. Battery acid will cause injuries if
it comes into contact with your eyes and skin.
Do not smoke when checking the battery acid. Avoid battery acid
touching your eyes and skin. Thoroughly rinse your eyes and skin with
clean water splashed with battery acid.
NOTICE
Information on battery upkeep and maintenance is contained in the
engine handbook.
The Diesel engine is equipped with a 28 V three-phase alternator. Due to the characteristics
of the three-phase alternator, special instructions for system with three-phase alternators must
be observed.
• Observe the correct polarity when connecting the batteries otherwise the diodes will
be destroyed.
• To determine whether a DC dynamo is supplying current, you can lightly touch the
earth. NEVER test a three-phase alternator in this way otherwise the semi-
conductors will be damaged.
• The preexcitation of the three-phase alternator is effected by the battery via the
battery charging lamp (A5c, 27Page). Therefore, a faulty charging lamp must be
immediately renewed to ensure a correct excitation.
Illustration 8

Charge the battery
1. The engine and ignition must be switched off.

2. Before disconnecting the battery, all electronic equipment must be
disconnected from the system, e.i. al plug connections must be unplugged.
3. Loosen and remove the terminal clamps before charging the battery. For safety
reasons, first remove the negative ( - ) terminal and then the positive ( + )
terminal.
4. After charging the battery, connect the terminal in the opposite sequence, i.e.
first the positive ( + ) and then the negative ( - ) terminal. Observe the correct
polarity when connecting the terminals.
5. Identification tags with numbers are attached to all ends of the wires in the
cable loom and these numbers correspond to the numbers on the machine's
wiring diagram. A further aid to identification are the colours of the wires
specified on the wiring diagram.
Greasing the battery terminals
1. Clean the battery terminals.

2. Check the terminal clamps for tightness.
3. Apply a thin film of battery terminal grease to the terminals to prevent corrosion.

HYDROSTATIC SYSTEM
Extreme cleanliness is a basic requirement for all maintenance and repair work on hydraulic
systems. Used oil, sand, dirt and metal chippings in hydraulic systems not only impair the
function and service life of the components, they also cause damage and eventually a com-
plete breakdown of the system.
Regularly check the hydraulic system for leakage and tight fitting of all threaded connections.
! CAUTION
All work on the hydraulic system such as tightening threaded
connections, exchanging filters, oil changes and renewing components
etc. (with the exception of checking the valve settings) may only be
carried out with the system completely depressurised, i.e. with the engine
switched off. Use clean plastic plugs to close the ends of any hydraulic
hoses or tubing which must be disconnected.
Do not use cleaning cloths or cotton waste to close hoses and tubes.
Illustration 9
When replacing hydraulic pumps and motors, the oil drain case must be filled with clean
hydraulic oil before putting them back into operation. Add oil through the drain case oil
connection (1).
Before putting the system back into operation, we recommend to flush the hydraulic lines; if
necessary, they must be dismantled .
A second possibility is to fit a high pressure filter with a filter mesh of 0.01 mm (10 um) into the
appropriate circuit instead of the hydro motor and filter the circuit for approx. 5 to 10 minutes
(check the filter's direction of flow).

High Pressure Filter for the Levelling Cylinders and Augers
Illustration 10
The filter cartridges on the high pressure filters for the levelling cylinders (1) and the
augers (2) must be changed for the first time at 125 operating hours and thereafter
every 1000 operating hours or at least once a year.

Feed Pressure Filter for the Travel Drive and Tamper Drive (only for VDT and VDT-V Screeds)
Illustration 11
The hydraulic oil is filtered by the feed pressure filters (3) installed on the pressure side of the
feed pumps. The feed pressure filters do not have a bypass which means that if the filter is
blocked, no unfiltered oil enters the closed circuit.
Instead of a bypass, the filters have integrated over pressure valves which open and allow the
hydraulic oil to flow back to the tank if the difference in pressure between filter inlet and filter
outlet is more than 5 bar.
With an increasing amount of dirt in the filter or with a too high oil viscosity at low temperatures,
the displacement of the variable pump in the main circuit will be delayed or there will be no
displacement at all. As a consequence: the paver's travel drive will lag or the paver will not
travel at all.
If this is due to cold oil, let the hydraulics run warm to reach normal operating temperature. If
this is due to a dirty filter, immediately change the filter cartridge.
Change the filter cartridge for the first time at 125 operating hours and thereafter every 1000
operating hours or at least once a year.
! CAUTION
After every filter change, run the Diesel engine for approx. 5 minutes at
idling speed, i.e. max. 800 1/min to build up the feeding pressure.

Cleaning the Vent Filter
Illustration 12
A vent filter is integrated in the filler cap for the hydraulic oil tank. The gauze must be cleaned
every 500 operating hours with compressed air; thereafter, moisten the gauze with a little
clean hydraulic oil.

Cleaning the Hydraulic Oil Cooler and Radiator
Illustration 13
To ensure an adequate cooling, the hydraulic oil cooler and engine radiator (2) must be
cleaned every 250 operating hours. To do this, soak them with a cold cleaning solvent and
spray them with a strong jet of water; better still, use a steam pressure cleaner.
Access to the radiator is gained through the duct at the rear of the hopper (1).
Carry out the cleaning work as described in the engine manufacturer's handbook.
NOTICE
When operating under very dusty conditions, it may be necessary to
shorten the cleaning intervals if the hydraulic oil temperature or the
engine temperature unduly rises.

TRANSMISSION GEARS
Check the pump distributor gear
Illustration 14
• Open and arrest the deck plate and side door.

• Check the tubing, hoses and transmission gear daily for leakage.
• Regularly check all threaded connections for tightness and visual damage.
• Check the oil level and/or change the oil (refer to Chapter 4 “Oil Change, Pump
Distributor Gear”, Page 4-34).
Check the travel drive transmissions
Illustration 15
• Check the transmission gears for leakage daily.

• Regularly check all threaded connections for tightness and visual damage.
• Check the oil level and/or change the oil (refer to Chapter 4 “Oil Change,
Transmission Gears”, Page 4-33).

DRIVE CHAINS AND V-BELTS

When performing maintenance on drive chains and V-belts, look for apparent damage and
renew all faulty parts.
Check at retension the engine V-belts one day after commissioning the new paver. Check the
V-belt tension once again after one week of operation and then at intervals of approx. four
weeks.
The narrow V-belts require tension to transmit power but should not be over tensioned as this
would lead to premature damage on the bearings.
The paver's drive chains must be regularly
• checked for sag and retensioned if necessary,

• checked for wear (e.g. connecting links and tooth flanks etc.),
• cleaned and lubricated.
When checking the drive chain tension, the connecting links, drag links and sprocket wheels
should also be checked for undue wear (damage to the tooth flanks) and renewed if
necessary.

Illustration 16
! CAUTION
When checking or tensioning the auger drive chains, you should drain
the condense water out of the drive case at the same time.
A threaded drain plug (10 mm A/F) is located at the lowest position on the
auger drive case for draining off any water collected in the case to
prevent damage to the auger drive system. Replace and tighten the drain
plug (1 & 2) after draining the water.
V-belts
Tension and renew the V-belts according to the instructions in the engine handbook.

Drive chains
Illustration 17
• Push the middle of the chain (2) with a screwdriver to check the tension.
• The chain must be retensioned if you can depress it by more than 10 mm.
• To do this, loosen the 4 screws (6) and the locking nut (7).
• Turn the tensioning screw on the hydro motor clockwise until you can depress the
chain by approx. 5 mm. Then tighten the locking nut (7).
Remarks: The bearings will wear prematurely if there is too much tension on
the drive chain.
• Now tighten up the 4 screws.

• Replace the protective cover.

Tensioning the conveyors
Illustration 18
Loosen the locking nuts (30 mm A/F), 2 locking per conveyor and tension the conveyor with
the 2 nuts (30 mm A/F) located on the front cross member on the paver's frame (1).
The conveyor must be equally tensioned so that both sides of the conveyor have the same
sag.
The sag should measure approx. 50 to 70 mm in a cold condition. After tensioning the
conveyor, retighten the locking nuts.

Auger Centre Drive
Illustration 19
To check the drive chain tension:
• Remove the cover (1), (4 hex bolts, 13 mm A/F (2)).

• Rotate the auger shaft to and fro and observe the tension on the drive chain. The
drive shaft on the hydraulic motor should not rotate when turning the auger shaft. The
tension on the auger drive chain is correct if there is approx. 5 [mm] of free play on
the circumference of the auger flight.
To tension the drive chain:
• Loosen the hex nut (24 mm A/F) (3).

• Loosen the 4 hex bolts (24 mm A/F) (4).
• Tension the chain with the hex bolt (3) (24 mm A/F) until the above value of approx.
5 mm is reached.
• Now tighten up the 4 hex bolts.
• Tighten up the hex nut.
• Replace the cover.

Auger Outer Drives
Illustration 20
To check the drive chain tension:
• Remove the cover (4 bolts 13 mm A/F) (1/2).

• Press the drive chain with a screwdriver; the chain should only yield slightly, tension
the chain if it is too slack. .
To tension the drive chain:
• Loosen the 4 bolts (19 mm A/F) and tension the chain with bolt (3/4) (19 mm A/F). .
• Rotate the auger shaft to and fro and observe the drive chain tension, the drive shaft
on the hydraulic motor should not rotate; the tension on the auger drive chain is
correct if there is approx. 5 [mm] of free play on the circumference of the auger flight.
• Tighten up the 4 bolts (19 mm A/F) (3).
• Replace the cover.

PRESERVATION FOR LONGER PERIODS OF STANDSTILL

Closely observe the measures to be taken described in the engine handbook for longer
periods of machine standstill.

LUBRICATION PLAN
All lubrication instructions contained in this lubrication plan only refer to the basic paver.
Lubricating instructions for the paving screed are contained in the operating manual for the
screed.
Park the paver on level ground before checking the oil levels and changing the oil. Always
drain off the oil at operating temperature and catch it in a suitable container.
Observe meticulous cleanliness when greasing the machine. Thoroughly clean the grease
nipple before applying the grease gun.
Slip guides and spindles must be greased or oiled as required especially after cleaning the
paver with grease and bitumen dissolving agents. Use a commercially available multi-purpose
quality grease.
The paver's chain drives must be lubricated once a week. Lubricating work can be done with
an oil can or aerosol can. Apply the lubricant between the link plates of the inner and outer
links. For normal operating conditions, use a quality brand of oil with a viscosity of SAE oils.
Choose an oil to suit your average ambient temperature:
Table 21:
Temperature Range SAE Viscosity Classification

-5 °C to +25 °C 30 VG 100
+25 °C to +45 °C 40 VG 150
+45 °C to +65 °C 50 VG 220
Once a month clean the chain drives with an oil and grease removing solvent; thereafter oil
the chains. At the end of the paving season, thoroughly clean all chains and sprockets and
preserve them with a special chain grease.
Remarks: After lubricating, remove the grease gun nozzle from the grease
nipple by turning the gun clockwise at an angle of approx. 30°. This will make
it easier to remove the grease gun without braking off the ball head on the
grease nipple.
Use extreme CAUTION when working in the vicinity of moving parts.
When paving bituminous materials, the conveyor and auger bearings must be immediately
lubricated at the end of paving work. To do this, run the conveyors and augers and apply
grease until it emerges from the cavities. Any paving material which may have penetrated the
seals will be forced out by the lubricant.
Grease points with daily intervals must be lubricated before washing the machine so that the
gaps in the bearings are closed with grease. Grease points with daily intervals must be
lubricated before washing the machine.
Do not direct the jet of water onto the bearings.

GREASE POINTS
The grease points 1 to 5 must be lubricated every 10 operating hours.
Lubricant:refer to ”Consumables”, page 7-2
Illustration 22

Illustration 23
Remarks: Grease points 1 to 5 do not apply to pavers equipped with the

central lubrication system.
1: LH & RH auger outer bearings on the basic auger (with centre auger drive); 2 grease nipples
2: Auger centre bearing (with auger centre drive); 3 grease nipples
1a: LH & RH auger outer bearings on the basic auger (with auger outer drives); 2 grease
nipples
2a: Auger centre bearing (with auger outer drives); 1 grease nipple
3: LH & RH auger outer bearings on the auger channel (at paving widths beyond 5.50 m); 2
grease nipples
4: Rear LH & RH conveyor drive shaft; 3 grease nipples
5: Front LH & RH conveyor idler; 2 grease nipples

The grease points 6 and 7 must be lubricated every 500 operating hours.
Lubricant: refer to ”Consumables”, page 7-2
Illustration 24
• Guide rollers on the LH & RH towing arms; 2 grease nipples

• Bearing for the LH & RH front track idler, 2 grease nipples.
4-Track Paver Titan 31 225/325

CENTRAL LUBRICATION SYSTEM (OPTION)
At least once a year, the grease lines must be disconnected directly from the users. Activate
the central lubrication system and check whether grease emerges from the grease lines. Fur-
thermore, all lubricating channels must be checked for a free passage of grease as illustrated
below.
Illustration 25
• Disconnect the lubricating line (Fig. 1 & 2) and screw in a normal grease nipple (Fig.
3).
• Apply grease with the grease gun (Fig. 4) until it emerges out of the cavities.
• Rectify any faults found in the lubrication system.
• Finally, remove the grease nipple and reconnect the grease line (Fig. 1).

OIL CHANGE, TRANSMISSION GEARS
Illustration 26
Quantity: 2 litres per transmission gear

Quality: refer to ”Consumables”, page 7-2
1. Park the paver on level ground and remove the cover plate (1)
2. The oil level plug (1) is positioned horizontally.
3. Unscrew and remove the oil level plug (1).
4. The oil level must reach the lower edge of the hole for the oil level plug (1) (the
oil level is then correct).
5. Top up with transmission oil if the oil level is too low.
6. After checking the oil, replace and tighten the oil level plug (1) and the oil filler
plug (2).
7. Replace the cover plate (1).

OIL CHANGE, PUMP DISTRIBUTOR GEAR
Illustration 27

Quantity: 1.25 litres

Check the oil level:
• Open the engine bonnet

• Remove the oil dip stick (11a).
• Use a non-fibrous clean cloth to wipe the dip stick dry and ten return it into the hole
in the housing.
• Remove the dip stick once again and check the oil level.
• The oil level is correct if it is between the MAX and MIN marks on the dip stick.
• The oil level is too low if it is just above the MIN mark on the dip stick (the oil level
should never be below the MIN mark).
• Top up or drain off oil to the correct level.
• Return the dip stick into the hole on the housing.
Draining the Oil: Unscrew and remove the filler plug with dip stick ( 11a) so that air enters the
gear and lets the oil trickle out. Then unscrew and remove the drain plug (11c on the LH side
of the paver) and catch the oil in a suitable container.
Filling the Oil: Fill 1.25 litres of transmission oil MB 90 through the filler plug (11a). Check the
oil level with the dip stick as previously described.

OIL CHANGE, HYDRAULIC SYSTEM
Illustration 28

Quantity: 205 litres to fill to complete system; approx. 160 litres for an oil change
Table 29:
Temperature Range SAE

below 0°C 10 W
-10 °C to +15 °C 20W/20
0 °C to +35 °C 30
+25 °C to +50 °C 40
-20 °C to +30 °C 10W/40
Check the oil level: Sight glass on the hydraulic oil tank.
Remarks: If the paver has a Variomatic screed, completely retract the

screed to check the oil level.
Draining the Oil: Drain the oil at operating temperature. Flush the tank to remove any oil
sediment (1).
Catch the oil in a suitable container. Take the hose from the tool kit and connect it to the drain
valve on the bottom of the hydraulic tank. Tighten the threaded connection (12b) until the oil
trickles out of the hose.
Filling the Oil: Fill oil through the filler neck (12c) on the top of the oil tank.
After an oil change, let the Diesel engine run for approx. 5 minutes at idling speed (max. 800
1/min) to let any air escape from the hydraulic lines.

OIL CHANGE, DIESEL ENGINE
Illustration 30: Engine Oil Drain Hose
Details of maintenance and consumables are contained in the engine handbook.
Remarks: The oil consumption may be slightly higher than normal on

new engines during the initial running in period of approx. 200 hours.
Therefore, check the oil level twice a day during the running in period.
If the paver has an operator's cabin, the engine oil will be used for the cab heating system.
Before draining the oil, turn the cab heating to the "full ON" position and let the engine run for
at least 1 minute with the heating full on. Fill new engine oil with the heating switched to the
"ON" position.
Thereafter, run the engine for at least 1 minute with the heating switched "ON". Then switch
off the engine and check the oil level in the oil sump; top up oil to the MAX mark on the dipstick
if necessary.
Further instructions for maintenance work and adjustments on the Diesel engine such as
cleaning the fuel filter, the fuel feed pump, the tappet clearance and checking the fuel injectors
etc can be taken from the appended engine handbook.

CHAPTER 5 - TROUBLE
SHOOTING

Chapter 5 TROUBLE SHOOTING
TROUBLE SHOOTING
! WARNING
When trouble shooting, it is absolutely essential that you read and strictly
observe the safety instructions contained in Chapter 1 “Safety”, Page 1-
2 of this manual.
Improper paver operation and maintenance are the most frequent causes of faults and
breakdowns. If a breakdown occurs, first read the operating manual and especially the chapter
on maintenance.
Notify your service technician or distributor if you cannot locate the cause of the problem or
required assistance when replacing faulty parts.

TROUBLE SHOOTING Chapter 5
TROUBLE SHOOTING
Fault Possible Cause Fault Clearance

Engine does not start Emergency STOP button Pull up the emergency STOP
depressed button and press the ON button
(319Page).
Fuse F7 has blown Check and replace the fuse F7
No set speed value on the Check the set value on X1/44
speed potentiometer (0-10 V), rectify the wiring fault
or replace the potentiometer
Spring loaded brake cannot be Check the feed pressure
released (approx. 30 bar). Check the
solenoid Y10, LED illuminates
when the brake is
released.Check the wiring and
rectify the fault.
Machine will only Short circuit or failure on the Check the wiring for short cir-
travel in one direction proportional solenoids for the cuits and damage.
travel drive pumps Check the drive lever (S24).
27Page
Check the solenoids on the
valves (Y1.1, Y 1.2, Y2.1, Y2.2).
Forward travel over a short dis-
tance is possible as follows:
Swap the cable plugs for for-
ward and reverse travel on the
solenoid for the travel drive
pump (upper to lower and vice
versa).
If the problem still occurs, the I/
O module for the travel drive is
faulty.
The travel speed can- Short circuit or failure on the Check the terminal voltage (X1/
not be altered speed potentiometer 45 = 10 V; X1/44 = 0-10 V).
Machine veers Speed sensors have been Swap XE2/13 with XE2/14 in
sharply to the left or interchanged the electronics.
right
Auxiliary control K 29 , K 11 or K 10 faulty or Check the fuse F7.
No function has been faulty current circuit Check the relays K29, K10 and
allocated to this key K 11
Check the terminal voltage as
per the wiring diagram.


Machine does not Control lamp for the speed Check the cable plugs on the
travel straight ahead sensor flashes sensor for tight fitting.
(faulty sensor or fault in the
wiring to the sensor)
Steering potentiometer not Check the terminal voltage X1/
adjusted correctly 48 and X1/49 (when travelling
straight ahead, the voltage must
be below 0.1 V).
Diesel engine runs at a too low Check the nominal speed
speed
Short circuit or failure on the Check the terminal voltage X1/

steering potentiometer R17/18 46 / 51 (10 V).
Check the set value X1/48 (0 -
10 V for LH turn).
Check the set value X1/49 (0 -
10 V for RH turn).
Replace the faulty wiring if nec-
essary.
Replace the steering potentiom-
eter if necessary.
Faulty solenoids on the travel Check the resistance on the
drive pumps solenoids
(both sides should have almost
the same value).
Machine cannot be No set value on the steering Check the terminal value (set
steered potentiometer value)
(X1/48 steering left 0 - 10V;
X1/49 steering right 0 - 10 V).
Rectify the terminal fault or
replace the potentiometer.
Speed cannot be Failure in the power supply to Check the fuse F9, check the
switched to transport the solenoids terminal voltage (X1/89 = 24 V;
speed X20.5/3 = 24 V; X20.5/1 and 2 =
12 V).
Check solenoid Y3 and Y4, LED
illuminates in the transport
speed.
"Turning-on-the-spot" Paver switched to transport Switch to paving speed stage
does not function speed stage (S6).
Faulty switching contact Check the terminal voltage
(faulty switch S77 or power not
supplied to X1/57 24 V).


Machine veers to one Current on the solenoids for the Offset Adjustment:
side when starting travel drive pumps is not set With the offset adjustment, the
correctly. starting values are calibrated for
the hydraulic pumps on the
Only carry out the offset
travel drive system. If a faulty
adjustment at operating
function occurs (e.g. sensor
temperature
error), the paver will start
moving slowly. In this case,
the offset adjustment proce-
dure can be immediately
stopped by moving the drive
lever or pressing the emergency
STOP button. For this reason,
it is absolutely essential that
the operator remains on the
operator's platform during the
offset procedure (approx. 2 to
3 minutes for each side).
Change the electronics to the
programming mode (Move the
plug-in bridge from X1/115-X1/
116 to X1/116-X1/117).
Start the offset adjustment on
the LH side by moving the drive
lever forwards.
During the calibration, the LH
sensor will flash and will perma-
nently illuminate when the cali-
bration is finished.
Start the offset adjustment on
the RH side by moving the drive
lever backwards.
During the calibration, the RH
sensor will flash and will perma-
nently illuminate when the cali-
bration is finished.
Finalise the offset adjustment
procedure by moving the plug-in
bridge from X1/116-X1/117
back to X1/115-X1/116.
Now start the machine moving
in the paving speed stage.
Repeat the offset adjustment if
the machine starts with irregular
movements.
Contact your nearest service
technician if the fault cannot be
rectified after several attempts
at the offset adjustment proce-
dure.

Fuses and Relays

The fuses and relays are housed in a cabinet on the rear of the control column.
Illustration 6:
Table 1:

1 Fuses Allocation as per overview (3)
2 Relays Allocation as per overview (3)
3 Allocation of fuses and relays
NOTICE
Replace a blown fuse with a fuse of the same amperage. If the fuse has
not blown, the fault may be in that particular circuit. Contact your service
technician or distributor if the fuse blows in the same circuit several
times without a recognisable cause.

Towing the Paver
! CAUTION
It is only permitted to tow the paver with a tow bar at a slow towing speed
of approx. 10 m/min over a short distance to remove the machine from the
danger zone or tow it to a low bed loader.
Ensure there are no persons or objects in the danger zone. Observe your
locally prevailing laws, regulations and the traffic code when towing the
paver. There is a danger of crushing and serious personal injury when
preparing the paver for towing.
Ensure the crawler tracks do not skid. The paver can only be steered and
guided by the towing vehicle if the Diesel engine has broken down.
Before unhitching the tow bar, ensure it is not under tension and the
paver is secured against moving by applying the spring loaded brake or
by wheel chocks.
Due to the hydrostatic travel drive, it is not permitted to tow start the
Diesel engine if the electric starter has broken down. Any attempt to tow
start the Diesel will cause damage to the hydrostatic drive system.

MANUALLY RELEASING THE PARKING BRAKE

Illustration 7:
• (1) = Test connection

• (2) = Brake valve
• (3) = Valve unit
• (4) = Brake connection
• (5) = Manometer
• (6) = Brake
1. Connect the manometer to the test connection (1) on the RH drive motor.
2. Remove the brake connection (4) from the brake valve (2).
3. Close the brake valve (2).
4. Screw the brake connection (4) onto the valve unit (3); then close the brake
connection. When doing this, the lines must not run dry.
5. Connect the grease gun to the grease nipple on the valve unit (3).
6. Keep pressing the grease gun to pump grease into the line until the manometer
(5) shows a pressure of 30 bar. The spring loaded brake (6) is now released.
7. After towing the paver, return the brake system to its original condition.

RELEASING THE HYDRAULIC DRIVE MOTORS TO RUN FREELY

Illustration 8:
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 (2). The oil can then flow freely in the circuit.
1. Loosen the lock nuts on both adjusting screws (1).

2. Screw in the adjusting screws (1) until they are flush with the lock nuts.
3. Retighten the lock nuts.
4. Unscrew the adjusting screws to their original positions and secure them with
the lock nut as soon as the paver is ready for operation.

REMOVING PAVING MATERIAL FROM THE AUGER CHANNEL

Illustration 9:
The augers can be manually controlled using the two levers (1) if a breakdown or jamming
occurs in the hydraulics. Using this manual auger control feature you can remove paving
material from the auger channel before towing the paver.

CHAPTER 6 - TECHNICAL DATA

Chapter 6 TECHNICAL DATA
Technical Data
TITAN 225
GENERAL DATA
Sales and Model Description Titan 225

Engine Deutz Diesel BF6M 1013 with turbo charger
Titan 225: P=100 kW at 2300 1/m
Titan 225EPM: P=112 kW at 2300 1/min
Fuel tank 236 litres
Paving output Up to 600 t/h, depending on job-site conditions,
paving width and paving material
Paving thickness Up to 300mm
Travel drive 2 electronically controlled hydraulic circuits (each
with a variable pump with proportional control and
a variable motor with 2-stage adjustment)
Auxiliary control via potentiometer
Paving speed 0-16 m/min
Transport speed 0-3.6 km/h
Crawler unit Crawler tracks with rubber track pads, 9 track roll-
ers, ground contact area approx. 2900 x 305 mm
Hinge mounted road scrapers
Hopper Hopper capacity approx. 13.5 l
Hopper locks operated from the platform, hopper
wings hydraulically opened and closed
Conveyor system Paddle type control switches for the conveyors,
ultrasonic sensors for the augers,
4 independent hydraulic circuits for the LH & RH
conveyors and LH & RH augers
Height of conveyor tunnel 373 mm
Hordox bolt-on hopper floor plates
Augers with hydraulic or mechanical height ad-
justment (+/-65mm)
Augers reversible

TECHNICAL DATA Chapter 6
Hydraulics Power drive: Twin distributor gear mounted on

the flywheel side, no pumps on the spur gear side
Reduced leakage by using hydraulic hoses
Only pressure line filters are used
Electrics Cable looms used for excellent overview and lay-
out
Flexible cable duct used for routing the cables on
the platform
Battery master switch
4 working lights
Option: Generator up to 34 kW
Weight With VB 78 screed: up to 5.00 m: approx. 16.8 t
to 7.50 m: approx. 17.6 t
With MB 122 screed: up to 2.50 m: approx. 14.9 t
Standard range of supply Railings with seat console and sun roof, cross-
sliding control panel, 2 deluxe seats, tool kit and
continuous towing arms
Options Side curtains for sun roof, orange warning bea-
con, cab with heating, voltage regulator for 12 V
levelling system, 2 additional rear working lights,
56 mm spacer blocks for the towing arms, screed
anti-climbing lock, screed assist, central lubrica-
tion system, emulsion spraying system for clean-
ing, Pave Control, analogue or digital levelling
system, multi-foot levelling beam, levelling tube,
spray gun for cleaning, ThermoControl for
screed heating, Diesel heating system for Vario
screeds

NOISE AND VIBRATION VALUES
Titan 225
Noise Level
The following sound levels were determined according to the provisions of 1.7.4 (f), Annex
1 of the EU Directives for Machinery 98/37/EC:
Equivalent continuous A weighted sound power level on the operator's platform: 90 dB(A)
Guaranteed maximum A weighted sound power level on the machine: Lw = 110 dB(A)
These measurements were made according to ISO 6394, ISO 6396 and ISO 6395 at the
nominal speed specified by the manufacturer. The noise values may vary depending on
the type of screed fitted to the paver, the paving conditions and the paving material.
Therefore, the actual values reached during paving work may deviate from the values
specified.
Stress on the Operator caused by Vibrations
The following values were determined according to the provisions 3.6.3 (a), Annex 1 of the
EU Directives for Machinery 98/37/EC:
Entire body vibrations on the operator's platform: The weighted effective value of
accelerations to which the body is exposed does not exceed 2.5 m/s².
The measurements were made according to ISO 5349 and ISO 2631 with the machine
operating at the maximum vibration amplitude and maximum frequency.

DIMENSIONS
Illustration 7: Dimensions Titan 225

TITAN 325
GENERAL DATA
Sales and Model Description Titan 325

Engine Deutz Diesel BF6M 1013 with turbo charger
P=133 kW at 2300 1/m
Fuel tank 236 litres
Paving output Up to 700 t/h, depending on job-site conditions,
paving width and paving material
Paving thickness Up to 300mm
Travel drive 2 electronically controlled hydraulic circuits (each
with a variable pump with proportional control and
a variable motor with 2-stage adjustment)
Auxiliary control via potentiometer
Paving speed 0-16 m/min
Transport speed 0-3.6 km/h
Crawler Unit Crawler tracks with rubber track pads, 9 track roll-
ers, ground contact area approx. 2900 x mm
Hinge mounted road scrapers
Hopper Hopper capacity approx. 13.5 l
Hopper locking bolts actuated on the operator's
platform
Hopper wings hydraulically opened and closed
Conveyor system 4 independent hydraulic circuits for the LH & RH
conveyors and LH & RH augers
Paddle type control switches for the conveyors,
ultrasonic sensors for the augers,
Hordox bolt-on hopper floor plates
Height of conveyor tunnel 373 mm
Augers with hydraulic or mechanical height ad-
justment (+/-65mm)
Augers reversible

Hydraulics Power drive: Twin distributor gear mounted on

the flywheel side, no pumps on the spur gear side
Reduced leakage by using hydraulic hoses
Only pressure line filters are used
Separate systems for VB resp. VDT-V, MB
screeds
Separate adaptation for auger length
Electrics Cable looms used for excellent overview and lay-
out
Flexible cable duct used for routing the cables on
the platform
Battery master switch
4 working lights
Option: Generator up to 34 kW
Weight With VB 78 screed: up to 5.00 m: approx. 17.0 t
With VB 88 screed: up to 6.00 m: approx. 17.4 t
With VDT-V78 screed: up to 5.00 m: approx. 17.3
t to 9.00 m: approx. 19.1 t
With VDT 121 screed: up to 2.50 m: approx. 15.1
t to 9.00 m: approx. 18.7 t
With MB 122 screed: up to 2.50 m: approx. 14.9 t
to 10.00 m: approx. 18.1 t
Standard range of supply Railings with seat console and sun roof, cross
sliding control column, 2 deluxe seats, tool kit,
continuous towing arms for VB screeds or split
towing arms for VDT and MB screeds
Options Side curtains for sun roof, orange warning bea-
con, cab with heating, voltage regulator for 12 V
levelling system, 2 additional rear working lights,
56 mm spacer blocks for the towing arms, screed
anti-climbing lock, screed assist, central lubrica-
tion system, emulsion spraying system for clean-
ing, Pave Control, analogue or digital levelling
system, multi-foot levelling beam, levelling tube,
spray gun for cleaning, ThermoControl for
screed heating, Diesel heating system for Vario
screeds

NOISE AND VIBRATION VALUES
Titan 325
Noise Level
The following sound levels were determined according to the provisions of 1.7.4 (f), Annex
1 of the EU Directives for Machinery 98/37/EC:
Equivalent continuous A weighted sound power level on the operator's platform: 85 dB(A)
Guaranteed maximum A weighted sound power level on the machine: Lw = 106 dB(A)
These measurements were made according to ISO 6394, ISO 6396 and ISO 6395
at the nominal speed specified by the manufacturer. The noise values may vary depending
on the type of screed fitted to the paver, the paving conditions and the paving material.
Therefore, the actual values reached during paving work may deviate from the values
specified.
Stress on the Operator caused by Vibrations
The following values were determined according to the provisions 3.6.3 (a), Annex 1 of the
EU Directives for Machinery 98/37/EC:
Entire body vibrations on the operator's platform: The weighted effective value of
accelerations to which the body is exposed does not exceed 2.5 m/s².
The measurements were made according to ISO 5349 and ISO 2631 with the machine
operating at the maximum vibration amplitude and maximum frequency.

DIMENSIONS
Illustration 8: Dimensions Titan 325


CHAPTER 7 - CONSUMABLES

Chapter 7 CONSUMABLES
Consumables
Lubrication is a major element of preventive maintenance and has a significant effect on the
working life of the paver. Regularly lubricating moving parts will reduce the possibility of a
breakdown cause by a failure of mechanical components. We recommend the use of
genuine lubricants to achieve an optimum working life and performance of the paver.
Different lubricants are required to lubricate the paver and its integrated assemblies. This
chapter includes a table of assemblies to be lubricated and the lubricant required.
If not otherwise specified, the oil levels must be checked as follows: Park the machine on level
ground and check the level when the oil is cold.
The oil must reach the lower edge of the filling hole on oil check points with a threaded oil level
plug.
If not otherwise specified, the grease nipples are designed according to SAE-STANDARDS.
Lubricate open grease nipples until grease emerges out of the nipple.
Applying excessive lubricant to the grease nipple will not damage the grease nipple or its
assembly. Insufficient lubricant will, however, shorten the component's working life.
If not otherwise specified, lubricate all components without grease nipples (rods, bolts and
levers etc.) once a week with oil. A thin film of engine oil will achieve the required lubrication
and avoid rust. An anti-seizing solvent can be used if rust or corrosion has formed. Otherwise
the component must be cleaned before lubricating.
Worn or damaged grease nipples must be replaced if the grease gun cannot be connected or
the ball in the nipple has jammed.
In addition to the regular lubricating intervals, carry out other inspection and maintenance work
at the same time. This will avoid more serious damage occurring on the assemblies.
1. Before starting maintenance work, clean all threaded connections, caps and
plugs etc with a non-flammable and non-toxic cleaning solvent so that dirt
cannot penetrate the system during work.
2. Drain off all oils at operating temperature.
3. When carrying out lubricating work at the prescribed intervals, check and
ensure that all nuts, bolts and screws are correctly tightened.
4. Make a random inspection of threaded connections and nuts and check
whether they are tightened to the correct torque. If any loose connections are
found, then check and tighten all threaded connections, nuts and bolts.
5. If damage is found during maintenance work, then the machine must be shut
down until the faults are rectified. Notify your local distributor if necessary.

CONSUMABLES Chapter 7
List of Fuel Oils and Lubricants
! WARNING
Health and environment hazard when handling hazardous materials
Closely observe Chapter 1 “Precautions for Handling Hazardous Goods”,

Page 1-8.
Table 1:
Description Application Quantity Specification

Engine oil Diesel engine 20.5 litres SAE 10W-40ACEA E4-99 / E6-04
Hydraulic oil hydraulic system 160 litres HVLP 100, DIN 51524-3
Hydraulic oil tensioning cylinders 2 x 0.5 litres HVLP 100, DIN 51524-3
Gear oil transmission gears 4 litres SAE 90, ca. 15°E / 50°C
Gear oil pump distributor 1.5 litres SAE 90, ca. 15°E / 50°C
gear
Grease vibrator bearings, As required High Temperature Grease
tampers, auger
bearings, conveyor
bearings and other
grease points
Diesel fuel Diesel engine (fuel As required CEN EN 590 DIN 51601 BS 2869:
tank) A1, A2 ASTM D975-88: 1-D, 2-D
NATO Code: F-54, F-75
Engine coolant Diesel engine 17 litres Refer to the engine handbook
(radiator)
NOTICE
All quantities are reference values which may vary within a series of
machines. After changing or topping up fluids, check the fluid level and
correct it if necessary.
Contact your nearest distributor or the manufacturer directly if your

machine is filled with biodegradable fluids or you wish to change to such
fluids.

Chapter 7 CONSUMABLES

CHAPTER 8 - TORQUES FOR
THREADED CONNECTIONS

Chapter 8 TORQUES FOR THREADED CONNECTIONS
TORQUES FOR THREADED CONNECTIONS
TABLE OF TORQUES - ISO

The following table of torques is recommended for nuts and bolts with a metric ISO strength
capacity and property class of 8.8 and more. If other torques are required, they will be
specified in the text for that particular component.
Remarks: The torques apply to galvanized and zinc coated dichromate

bolts.
TORQUE
Bolt Size
lbs.-ft. Nm
M6 x 1.0 9 12
M8 x 1.25 21 28
M10 x 1.5 45 61
M12 x 1.75 79 105
M14 x 2.0 125 170
M16 x 2.0 195 265
M20 x 2.5 380 515
M24 x 3.0 660 895
M30 x 3.5 1310 1780
M36 x 4.0 2290 3100

GLOSSARY OF TERMS
Track Paver Titan 225/325 I

Glossary of Terms
Alphabetical Index D
Daily procedure at the end of paving work . .
A 3-61
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Additional. . . . . . . . . . . . . . . . . . . . . . . . 2-34 Diesel engine
Anti . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Oil change ........................................... 4-38
Application Dimensions
intended .................................................1-4 Titan 225 ............................................... 6-5
unintended use ......................................1-4 Titan 325 ............................................... 6-9
At the end of paving work . . . . . . . . . . . 3-61 direction . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Auger mode selection . . . . . . . . . 2-12, 2-17 Direction Indicator . . . . . . . . . . . . . . . . . 3-51
Auger overmodulate . . . . . . . . . . . . . . . 2-21 Distributor . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Auger reverse rotation . . . . . . . . . . . . . 2-13 Distributor augers
Auger, operation . . . . . . . . . . . . . 2-12, 2-17
Auger height........................................ 3-42
extensions ........................................... 3-46
Filter .................................................... 4-16
B Mix flow control ................................... 3-49
batteries. . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 with centre drive.................................. 4-25
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
with outer drives .................................. 4-26
charging ...............................................4-14 Drive chains . . . . . . . . . . . . . . . . . . . . . . 4-21
greasing the terminals .........................4-14 Drive lever . . . . . . . . . . . . . . . . . . . . . . . 2-14
master switch ......................................2-33 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
E
C Electrical power supply
Central . . . . . . . . . . . . . . . . . . . . . 2-24, 4-32 ON / OFF .............................................. 3-7
Check the engine oil level . . . . . . . . . . . 4-11 Electrical system
Clean Maintenance ....................................... 4-13
hydraulic oil cooler and radiator ..........4-19 Electrics . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
vent filter ..............................................4-18 Electronic levelling system . . . . . . . . . . 2-32
clean . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Emergency Control . . . . . . . . . . . . . . . . 3-28
Cleaning the Machine . . . . . . . . . . . . . . 4-10 Emergency operation . . . . . . . . . 2-38, 3-28
Commissioning the Paver Emergency STOP
check .....................................................3-6 indicated on the control panel .............. 2-8
Consumables . . . . . . . . . . . . . . . . . . . . . 7-2 release ................................................ 2-10
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 switch .................................................. 2-10
Control Column, Cross Sliding . . . . . . . 3-16 Emission . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Control panels Emulsion . . . . . . . . . . . . . . . . . . . . 2-3, 2-26
external ................................................2-20 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 jump starting ....................................... 3-21
Conveying the mix Engine coolant level . . . . . . . . . . . . . . . . 2-8
to one side ...........................................3-59 Engine oil pressure . . . . . . . . . . . . . . . . . 2-8
Conveyors Engine oil temperature . . . . . . . . . . . . . . 2-7
operation ................................... 2-12, 2-17 Engine speed . . . . . . . . . . . . . . . . . . . . . 2-19
tensioning ............................................4-24 Engine, start. . . . . . . . . . . . . . . . . . . . . . 2-14
conveyors . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Important instructions ......................... 3-19
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 with the starter batteries ..................... 3-20
Corrosion protection . . . . . . . . . . . . . . . . 1-8 Engine, stop . . . . . . . . . . . . . . . . . 2-14, 3-23
Crawler . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
II Track Paver Titan 225/325

Glossary of Terms
External . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

External control panels . . . . . . . . . . . . . 2-20 Hydraulic drive motors, free running . . . . 5-9
Hydraulic oil
temperature........................................... 2-8
F hydraulic system
Feed pressure filter for travel drive and Oil change ........................................... 4-36
tamper drive . . . . . . . . . . . . . . . . . . . . . 4-17 Hydrostatic System . . . . . . . . . . . . . . . . 4-15
Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
first aid box I
compartment ............................... 2-3, 2-22 Identification Plate
safekeeping ...........................................0-4 Engine ................................................... 0-4
First Oil Change . . . . . . . . . . . . . . . . . . . 4-6 Machine ................................................ 0-3
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Front . . . . . . . . . . . . . . . . . . . . . . . 2-3, 3-34 Ignition switch . . . . . . . . . . . . . . . . . . . . 2-14
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Important information
Tank ............................................. 2-3, 2-23 general .................................................. 1-3
Fuel filter Important instructions
draining off the condensed water ........4-12 Maintenance ......................................... 4-2
Fuel level Operation .............................................. 3-3
indicated on the control panel ...............2-7 Instruments . . . . . . . . . . . . . . . . . . . . . . . 2-2
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Fuses . . . . . . . . . . . . . . . . . . . 2-35, 2-38, 5-6
L
Lashing . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
G Lashing the Machine on the Vehicle . . . 3-66
gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Levelling Cylinders
Gas bottle Filter .................................................... 4-16
connection ...........................................2-31 Levelling System . . . . . . . . . . . . . 2-32, 3-51
support...................................................2-3 Levelling system . . . . . . . . . . . . . . . . . . 2-18
tensioning belt .....................................2-31 List of Fuel Oils and Lubricants . . . . . . . . 7-3
Gas heating . . . . . . . . . . . . . . . . . . . . . . 2-30 Live electric cables
hose routing .........................................1-11 procedure when touching the cables . 1-14
precautions ..........................................1-10 Loading
Precautions for gas leakage ...............1-13 by crane .............................................. 3-62
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 on a vehicle with ramps ...................... 3-65
General Data Lubricant list. . . . . . . . . . . . . . . . . . . . . . . 7-3
Titan 225 ...............................................6-2 lubricating . . . . . . . . . . . . . . . . . . . . . . . 3-32
Titan 325 ...............................................6-6 Lubrication . . . . . . . . . . . . . . . . . . . . . . . 4-28
Grease. . . . . . . . . . . . . . . . . . . . . . 1-8, 4-29
M
H Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hazardous goods MAINTENANCE . . . . . . . . . . . . . . . . . . . 4-2
handling ......................................... 1-8, 4-6 Maintenance
Hazards before starting ....................................... 4-5
special ...................................................1-8 chart ...................................................... 4-7
Hopper. . . . . . . . . . . . . . . . . . . . . . 2-3, 3-36 Electrical system ................................. 4-13
Hopper wings . . . . . . . . . . . . . . . . . . . . 2-13 work..................................................... 4-10
horn . . . . . . . . . . . . . . . . . . . . . . . 2-13, 2-21 maintenance
hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 First Oil Change .................................... 4-6
Track Paver Titan 225/325 III

Glossary of Terms
Manually releasing the parking brake . . . 5-8

Manually removing paving material . . . 5-10
P
master switch . . . . . . . . . . . . . . . . . . . . 2-33 Panel, control . . . . . . . . . . . . . . . . . . . . . . 2-7
Mat . . . . . . . . . . . . . . . . . . . . . . . . 2-3, 2-25 Paver
Mat thickness lubricating............................................ 3-32
adjusting ..............................................3-53 refuelling ............................................. 3-30
adjustment ................................. 2-20, 2-21 securing .............................................. 3-66
Mat thickness is not correct . . . . . . . . . 3-58 setting up ............................................ 3-29
Material . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Towing the paver .................................. 5-7
Mix flow Paving . . . . . . . . . . . . . . . . . . . . . . 2-3, 3-52
Augers .................................................3-49 in contaminated areas .......................... 3-4
Conveyors ...........................................3-50 in the vicinity of overhead electric cables ...
Moba controller . . . . . . . . . . . . . . . . . . . 2-32 3-4
in the vicinity of railway lines ................ 3-4
in tunnels ............................................... 3-4
N mix segregation .................................. 3-58
Noise and Vibration Values on bridges ............................................. 3-5
Titan 225 ...............................................6-4 on slopes ............................................... 3-5
Titan 325 ...............................................6-8 Paving mix
conveyed too slow .............................. 3-60
to one side .......................................... 3-59
O Paving screed
Oil change extend/retract (Warning light) ............. 2-21
Diesel engine.......................................4-38 floating mode ...................................... 3-54
hydraulic system .................................4-36 operation ....................................2-21, 3-39
Pump distributor gear ..........................4-34 screed spacer blocks .......................... 3-42
transmission gears ..............................4-33 secure ................................................. 3-36
on-the-spot . . . . . . . . . . . . . . . . . . . . . . 3-27 Tensioning Device .............................. 3-40
Operating transport lock ...................................... 3-36
in auxiliary control ...............................3-28 Personnel responsibilities . . . . . . . . . . . . 1-7
Operating hour meter . . . . . . . . . . . . . . . 2-8 Platform
Operating Manual Control panel......................................... 2-7
safekeeping ...........................................0-4 operator's .............................................. 2-4
Operating Mode Automatic Power supply
paving ..................................................3-57 ON / OFF .....................................2-33, 3-7
setting ..................................................3-52 Preservation. . . . . . . . . . . . . . . . . . . . . . 4-27
Operation. . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Pressure . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Important instructions ............................3-3 Pump distributor gear . . . . . . . . . . . . . . 4-20
Operator . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Oil change ........................................... 4-34
Operator's Platform . . . . . . . . . . . . . . . . . 2-4
extending / retracting...........................3-14
setting up ...............................................3-8 R
Operator's Seat Raising and Lowering the Sun Roof . . . . 3-9
deluxe .......................................... 2-6, 3-18 Rapid lubrication . . . . . . . . . . . . . . . . . . 2-10
Standard ...................................... 2-5, 3-17 Receiving the machine, procedure . . . . . 0-3
ordering . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 refuelling . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Removing . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Removing paving material from the auger
channel . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
IV Track Paver Titan 225/325

Glossary of Terms
Responsibilities Torques . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

personnel ...............................................1-7 Tow point . . . . . . . . . . . . . . . . . . . 2-12, 2-18
user / contractor ....................................1-5 Tow point sinks down . . . . . . . . . . . . . . 3-59
Road . . . . . . . . . . . . . . . . . . . . . . . 2-3, 3-35 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Rotary sensor . . . . . . . . . . . . . . . . . . . . 2-13 Towing the paver . . . . . . . . . . . . . . . . . . . 5-7
Transmission gear . . . . . . . . . . . . . . . . . 4-20
Transmission gears
S oil change............................................ 4-33
transport lock . . . . . . . . . . . . . . . . . . . . . 3-36
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Trouble . . . . . . . . . . . . . . . . . . . . . . . 5-2, 5-3
Safety instructions
Turning . . . . . . . . . . . . . . . . . . . . . 2-11, 3-27
application specific ................................3-4
Safety precautions
when gas escapes ..............................1-13
when the machine touches live cables1-14
U
Schematic . . . . . . . . . . . . . . . . . . . . . . . 1-12 Unintended Use . . . . . . . . . . . . . . . . . . . . 1-4
Screed . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 User / contractor responsibilities . . . . . . . 1-5
screed . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 Using the machine for its intended use. . 1-4
Screed / Floating mode . . . . . . . . . . . . . 2-16
Screed anti-climbing lock . . . . . . . . . . . 2-16
Screed assist . . . . . . . . . . . . . . . . . . . . . 2-15 V
setting the pressure.............................3-60 V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Screed control . . . . . . . . . . . . . . . . . . . . 2-16 Vibrators . . . . . . . . . . . . . . . . . . . . 2-9, 2-27
Screed heating . . . . . . . . . . . . . . . . . . . 2-30
Screed raise and lower . . . . . . . . . . . . . 2-17
Screed spacer blocks . . . . . . . . . . . . . . 3-42 W
Seat Console, Extending and Retracting3-15 Warning beacon . . . . . . . . . . . . . . . . . . 2-34
Sockets . . . . . . . . . . . 2-35, 2-36, 2-37, 2-40 Warning Horn. . . . . . . . . . . . . . . . 2-13, 2-21
Speed potentiometer. . . . . . . . . . . . . . . 2-10 Welding work on the paver
Speed stage . . . . . . . . . . . . . . . . . . . . . 2-11
Important instructions ........................... 4-6
Spring loaded brake
Windscreen . . . . . . . . . . . . . . . . . . . . . . 3-13
indicated on the control panel ...............2-9 Working . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Starting . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Steering potentiometer . . . . . . . . . . . . . 2-15
STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
X
STOP material flow . . . . . . . . . . . . . . . . 2-21 Xenon. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Stopping . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Storage . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Sun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Switch Cabinet
operator's platform ..............................2-38
paver's rear wall ..................................2-39
T
Table of torques . . . . . . . . . . . . . . . . . . . 8-2
Tampers . . . . . . . . . . . . . . . . . . . . 2-9, 2-27
Technical Data . . . . . . . . . . . . . . . . . . . . 6-2
Threaded connections . . . . . . . . . . . . . . 8-2
tighten ..................................................4-10
Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Track Paver Titan 225/325 V

Glossary of Terms
VI Track Paver Titan 225/325

The warranty statement is provided within the manual kit shipped with the machine.
Ref. No. VOE21A1004217 English
CPN 80846710
Printed in Sweden CST
Volvo, Hameln

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Ref. No.

PROCEDURE WHEN RECEIVING THE MACHINE ..................................................................... 0-3

EXPLANATION OF THE SAFETY SYMBOLS ........................................................................... 1-2

INSTRUMENTS AND CONTROLS

MACHINE OVERVIEW ......................................................................................................... 2-3

Track Paver Titan 225/325 Ref. No. VOE21A1004217 1

IMPORTANT INSTRUCTIONS FOR OPERATION .......................................................................3-3

2 Track Paver Titan 225/325

IMPORTANT INSTRUCTIONS ................................................................................................ 4-2

Track Paver Titan 225/325 3

DRIVE CHAINS AND V-BELTS ......................................................................................4-21

TROUBLE SHOOTING ...................................................................................................5-3

TITAN 225 .........................................................................................................................6-2

LIST OF FUEL OILS AND LUBRICANTS..................................................................................7-3

TORQUES FOR THREADED CONNECTIONS

TABLE OF TORQUES - ISO ................................................................................................8-2

ALPHABETICAL INDEX .........................................................................................................9-II

4 Track Paver Titan 225/325

Track Paver Titan 225/325 0-1

Remarks:No part of this operating manual may be reproduced, stored in

Remarks:Machines may be illustrated in this manual equipped with

0-2 Track Paver Titan 225/325

PROCEDURE WHEN RECEIVING THE MACHINE

DATA REQUIRED FOR ORDERING SPARE PARTS

MACHINE IDENTIFICATION PLATE

Illustration 1: Machine Identification Plate

Track Paver Titan 225/325 0-3

ENGINE IDENTIFICATION PLATE

Illustration 2: Engine Identification Plate

SAFEKEEPING THE OPERATING MANUAL AND FIRST AID BOX

Remarks:Ensure the first aid box is always stored in this storage

0-4 Track Paver Titan 225/325

Track Paver Titan 225/325 1-1

EXPLANATION OF THE SAFETY SYMBOLS

The safety symbol "DANGER" indicates a

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IMPORTANT GENERAL INFORMATION

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INTENDED AND UNINTENDED USE

Remarks: There is no warranty for the safe operation of the paver if it is

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RESPONSIBILITIES OF THE USER / CONTRACTOR

• The machine is only operated for its intended use.

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RESPONSIBILITIES OF THE PERSONNEL

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INSTRUCTIONS FOR SPECIAL HAZARDS

PRECAUTIONS FOR HANDLING HAZARDOUS GOODS

Table 1: Precautions for Handling Hazardous Materials

Table 2: Precautions for Handling Hazardous Goods

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PRECAUTIONS WHEN HANDLING GAS HEATING SYSTEMS

Closely observe the following safety instructions to avoid serious injury

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Gas Hose Routing

Table 3: Schematic illustration of the propane gas heating system

1 Gas bottle with canopy 11 Ignition electrode

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SAFETY PRECAUTIONS WHEN GAS ESCAPES

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