Wey =Neteams SEY OPERATING INSTRUCTIONS SUPER 1100-3i / 1300-3i 1011 Seies 09.07.2013 Issue date 2325145_00_en © Joseph Vogele AG 2013, eyPublisher Joseph Végele AG Joseph-Végele-Strate 1 67075 Ludwigshafen Germany Phone: +49 (0) 6 21/81 05-0 http:iwww.voegele info Document name BAL_1011_2325145_00_en Translation of the original operating instructions First issue date 09.07.2013 Date of change 09.07.2013, Copyright © Joseph Vogele AG 2013 ‘The reproduction, distribution and utilization of this document as ‘well as the communication of the contents to others without express authorization is prohibted. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design. 2/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013ele ra ofcotent TABLE OF CONTENT 1 General. 4.01 Introduetion., 8 4.01.01 Changes / rights reserved. vn M4 1.01.02 Packaging and storage......... svttttnnniinetnnnnnnnnnnnncee 4.01.03 Markers and symbols used in these Instructions....--cccnsnnenenne sve 1.01.04 ‘Safety markers. 1.01.05 ‘Signal words..... 1.02 Documentation... ee 4.03 Usage 1.03.01 Oe vce 1.03.02 Reasonably foreseeable incorrect use. 15 4.03.03 Residual hazards. 1.03.04 Climatic conditions. 1.04 Protection of the environment... 1.05 Disposal... nnn seve . event 1.08 Declaration of conformit 407 Tyne plate on 1.08 Noise and vibration figures... svn sve 24 1.08.01 1.08.02 1.08.03 1.09 4.10 Personnel - qualifications and obligatiors....... sence sevnnnnteeeee 22 4.10.0 Personal safety equipmer 4.11 General safety instructions... eeennnnnninnnnnnntnnnnenennnese 25 4.11.01 ‘Safety manual, eee) 4.11.02 Instructions on electrical / electronic components. 112 Hazard af@. nnn svn 4.12.01 Safety distance between working area and road traffic 4.13 Labelling. 1.13.01 Labelling diagram. 4.13.02 Labels used, 2 Description... 201 Chassis / safety devices... cco snnsnennn 2.01.01 Operating instructions and watnings.....0.0.0ssen © Joseph Végele AG 2013 BAL_1011_2325145_00_en 3/289Table of content 2.01.02 Trim panels. 2.01.03 Lighting / warning features... oe 2.01.04 Safety devices. onnnnnnnnnnn 2.01.05 Chassis. 2.01.06 ‘Space for fire extinguisher... een 2.02 Operator's stand. 2.02.01 ‘Operator's consol 2.02.02 Vandalism protectior 2.02.05 Driver's seat with FallS nen 2.02.06 ‘Outer control stand. 2.02.07 Roof (option). 2.04 Engine / motor group.. 7 2.04.01 Engine compartment... 98 2.04.02 Fuel SUPPLY. . tnt OD 2.04.03 Exhaust system. 100 2.04.04 Combustion air / ain intake... 12 2.04.05 Cooling SYSteM nnn 103 2.05 Hydraulic oil feed. 2.05.01 Oil supply... 2.05.02 Pump distribution gearbox. 2.05.03 Pumps... 2.05.04 Control blocks. 2.05.05 Partial flow filter for bio-oil (option 2.08 Electrical system. 2.06.01 24 V power supply. 2.06.02 2.06.03 2.06.04 2.06.05 2.08 2.09 2.40 2.10.02 Matetial hopper. enemies A 2.10.03 Conveyors. 2.10.04 Distribution augers... enn 2.10.05 Ultrasonic distribution auger sensor (option) 211 Leveling Unit. nnn 241.01 NIVELTRONIC Plus® levelling unit (OptIOM) nner 126: 41268 BAL_1011_2825145_00_en © Joseph Végele AG 2013,ele ra ofcotent 2.11.01.01 2.11.01.02 213 2.13.01 2.13.02 ‘Shoulder nozzle. 214 Screed connections. 2.14.01 Tow point ram....... 2.14.02 Screed assist (option| 2.14.03 ‘Screed lock. 2.14.04 Electrical and hydraulic tractor / screed connection .....cneee 219 SorCOd. enn 3 Operation 3.01 General information. 3.02, Organising the workplace. 3.02.01 Unfolding the roof.. 3.01 Placing the road paver in operation. 3.04 Driving, stopping and turning the road raver... 3.05 Laying pavement. 3.05.01 Paving with AutoSct.. 3.06 Manoeuvting the road paVet....ronre ntti nee NOT 3.06.01 Raising / lowering and mechanically locking the screed, 148, 3.07 Cleaning and shutting down the road paver. 3.07.01 Fitting the vandalism protection. 3.08 Transporting and loading the road paver... 3.08.01 Raising and locking the hopper wall... . seventeen 158 3.08.02 Moving the awning (only SUPER 1300-3). 3.08.03 Folding in the roof... . sv 3.09 Towing the road paVel....cncnnnnsnne 3.10 Backup manual actuation, 3.11 Operating the NIVELTRONIC Plus® components (option)... 3.11.01 Ultrasoni¢ sensor... 4 Maintenance. 4.00 Special safety instructions... 4.01 Chassis / safety devices... 4.02 Operator's stand... 4.04 Engine / motor group. 4.04.01 Engine compartment. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 5/289Table of content 4,04.01.01 Checking the engine oil level. 4,04.01.02 Draining the engine cil 4.04.01.03 Changing the engine oil filter. 4,04.01.04 Filling the engine oil... 4,04.01.05 Checking the V-belt 4.04.01.06 Checking the belt tensior 4.04.01.07 Tensioning the engine v-belts. 4,04.01.08 Checking the engine mounting. 4.04.02 4,04.02.01 4.04.02.02 4.04.02.03 Bleeding the fuel system... 4.04.03 ‘Combustion air / air intake. 4.04.04 Cooling system. 4.04.04.01 Checking and topping up coolant... enenn neni BT 405 Hydraulic oil feed... enn a nn 188 4.05.01 Oil supply. 4.05.01.01 Changing the hydraulic Oil. nnn nnn 1BQ 4.05.01.02 Cleaning the fier screen, 4,05.01.03, Changing hydraulic oil fiters.. 198 1.05.02 Pump dietribution gearbox... 107 4.05.02.01 Changing the gearbox Oil eee neneennnn - oA 97 4.05.03 Changing partial flow filter for bio-ol (0ptiON). een vor 198 4.08 Electrical system. 4.06.01 24 V power supply. 4.06.02 ‘Switch cabinet / power supply / socket. 4.06.03 Generator. 4.06.03.01 Checking the belt tension... 4.06.03.02 Tensioning V-belts... wo 4.08 Advance driven a 4.08.01 Crawler... 4.08.02 Advance drive. 4.08.03 Adjusting the material deflector... 4.09 4.40 4.10.01 Push roller nn 4.10.02 Material hopper / entry fla 4.10.03 CONVEYONS ne 4.10.03.01 Tensioning the conveyor chai 4.10.03.02 ‘Tensioning the drive chain. 4.10.03.03 4.10.04 6/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013ele ra ofcotent 4.10.04.01 Tensioning the drive chain. 4.10.04.02 Cleaning the distribution augers.. 4.10.04.03 Grease the auger bearings. 411 Levelling unit... 413 Cleaner unit.. ene ene DOD 4.13.01 Cleaning the fitter screen. 222 4.13.02 Changing the filter cartridge. seven 224 404 4.14.01 Tow point fate nnn seen DOB 4.19 5.01.02.01 svn snot ve sve 22B 5.01.03 Dimensions.. 228 5.01.03.01 Drawings with dimensions... a 229 5.01.03.02 ‘Sound power level... ee) 5.01.04 Engine / motor group. 231 5.01.05 Hydraulic oil feed, 5.01.08 Electrical system... vntntittntnnninee svnneee D382 5.01.07 Advance OFIVE..n cece vtetettnnnnerereeneene BBD 5.01.08 ‘Conveyor unit / distributic 5.01.09 Levelling unit sventttntnnnninitnnnnnnnnnntnnnnnntnsnnnenees 282 5.01.10 Crane loading and load securemert... 233 5.01.10.01 Crane loading specifications.. 233 5.01.10.02 Load securement specifications... 234 5.02 Maintenance schedule......0.-0ensennnneneeenntnnnnne cesnnntneeene 285; 5.03 Tightening torques.....--0cenvnnennenernnnnnnnitinnntnnnnnnnninnnne ST 5.04 Lubricant chart. 5.05 Separate documentation... . 5.05.01 Documentation on the road paver. 5.05.02 Information material 5.06 Fuse assignments. ....cssnnninnnnnnnnne 6 Assembly and conversion. 6.02 Operator's stand... 6.02.01 Fitting and removing the roof. 6.09 Steering system... sone © Joseph Végele AG 2013 BAL_1011_2325145_00_en 71289Table of content 6.09.01 Fit, adjust and latch the steering system (direction indicator). 610 Conveyor Ut eee 6.10.01 Offsetting the push rollers... 6.10.02 Setting up the distribution auger 6.10.02.01 Overview of auger extension sizes available... 6.10.02.02 611 Levelling Unit. enn ~ 6.11.01 Fitting and setting up the NIVELTRONIC Plus® (option). 6.11.01.01 Fitting and adjusting the mechanical range probe.. 6.11.01.02 Fitting and setting up the ultrasonic long range sensor. 6.11.01.03 Fitting and setting up the ultrasonic sensor... 6.14 Screed connections. 6.14.01 ‘Adjusting the screed hight. CHANGES. 8/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el General Introduction 1 GENERAL 1.01 Introduction © | Inthis section you, as the operator, will find important instructions on the L_| operation of the machine and the use of these operating instructions. This VOGELE machine is a product from the wide range of VOGELE. road construction machinery. The extensive experience of VOGELE as well as the latest production and test methods guarantee the very high reliability of your machine. The ‘operating instructions belong to the machine! ‘These operating instructions are only valid in conjunction with the safety manual. Please note: ‘These operating instructions are written for the operator and the maintenance engineer on the construction site. ‘These operating instructions are intended to place you in the position to ‘operate the machire safely and to use its features to the full ‘They also provide instructions on the function of important attachments ‘and systems. ‘Specific terms are used in these operating instructions. To avoid misunderstandings, you should always use the same terms. Only qualified, instructed and trained personnel are allowed to work on this machine, The operating insuuctions, the safely anual and the slipulalions and. regulations applicable in the place of use must be observed (for example ‘accident prevention regulations). The use of these operating instructions will make it easier for you: ‘+ To familiarize yourself with the machine. ‘+ To avoid malfunctions due to incorrect operation. Observing the operating instructions: = Will help to prevent dangers. + Will increase refability of the machine when in use on the construction site. ‘= Will increase the service life of the machine. * Will reduce maintenance costs and downtimes. ‘Always deposit this Operating instructions within reach in the ‘compartment provided for it. ‘Should you receive further information on the machine from us, these instructions are also to be observed and attached to the operating instructions (for example additional technical information). you do not understand the operating instructions or specific sections, ‘you should ask us before you start the related activity. Joseph Végele AG is not liable for the safe function of the machine: ‘+ Onuse other than normal use. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 9/289Claims under warranty will not be accepted in case of: + Operating errors. + Incorrect maintenance. Claims under warranty can only be accepted if the use of approved diesel and engine oil can be proved. + Incorrect greases, oils or fuels, ‘+ Use for purposes that are not stated in the operating instructions. ‘The warranty and liabiity conditions in the general terms and conditions Published by Joseph Vogele AG are not extended by the above instructions. ‘We reserve the right to make changes without prior notice as a result of technical development. Machines with aftertreatment system (type name of machine ends with the letter "i") Use of unsuitable fuel results in destruction of the engine and failure of the machine. rte To ensure the reliability of engine and after-treatment system: * Only use fuel in accordance with EN 590 or ASTM 975-10 containing < 15 mglkg sulphur * Observe instruction labels on the filler. * Incase of doubts perform an fuel quality analysis. ‘An analysis setis available from your Wirtgen dealer. Order number: 2210004 Information and illustrations in these operating instructions are not allowed to be copied, distributed, or used for the purposes of competition. Translations are undertaken to the best of our knowledge. No liability can be accepted for translation errors or any resulting consequences; also not in the case that the translation was made by us or was commissioned by us. ‘The German text is and remains definitive forall ibilty claims and claims under the warranty. Allegal rights related to copyright are expressly reserved We wish you every success with your VOGELE machine! | Tees Separate crerating instructions forthe tractor and the screed ‘A functional road paver (in the context of the Machinery directive) is only produced on the permissible combination of tractor and screed, ‘The respective operating instructions are always related and both sets of ‘operating instructions are always to be observed together with the safety manual Ifyou use special machines, the original operating instructions for the standard machine and the supplementary operating instructions for the ‘special machine are applicable. The additional features of the special machine are explained in the supplementary operating instructions, 10/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el General Introduction 1.01.01 Changes / rights reserved ‘We make every effort to ensure these operating instructions are correct land up to date. To maintain our technological lead, it may be necessary to make changes to the product and its operation without notice. We ‘accept no liability for malfunctions, failures or any resulting damage. You must also observe any additional information supplied. 1.01.02 Packaging and storage To ensure adequate protection during shipment, the products have been ‘carefully packed, (On receipt of the goods, the packaging and the goods should be checked for damage. In the case of damage, the machines are not allowed to be placed in ‘operation. Damaged leads and connectors are a safety risk and must not be used under any circumstances. In this case please contact your VOGELE supplier. Ifthe machines are not placed in operation immediately after unpacking, they must be protected against moisture and dirt 1.01.03 Markers and symbols used in these instructions ‘The markers and symbols in these instructions are intended to help you to use the instructions and the machine quickly and safely. Intormation ‘These pieces of information provide you with information on the most effective and most practical utilisation of the machine and these instructions. Actions ‘The defined sequence of actions will make it easier for you to use the machine correctly and safely. Result Here you will find a description of the result of a sequence of actions. Item number on assembly illustration tem numbers on assembly illustrations are marked in the text with round brackets (). Item number on individual part illustration tem numbers on ilustrations of specific parts are marked in the text with ‘square brackets []. 1.01.04 Safety markers The safety marker provides a visible indication of a source of danger. ‘The safety markers in all the technical documentation comply with the harmonised standard EN 61310 part 2: Safety of machinery. Indication, marking and actuation. Requirements for marking and EU directive 92/58/ EEC - minimum requirements for the provision of safety and/or health ‘signs at work (safety regulations). © Joseph Végele AG 2013 BAL_1011_2325145_00_en 11/269peste y as invoducton o Warning of a general hazard This warning marker is used before activities during which risks could atise for several reasons. Warning of hazardous electrical voltage This waming marker is used before activities during which there are risks of an electric shock, possibly with fatal consequences. Warning of suspended load This waming marker is used before activities during which there are risks due to falling objects, possibly with fatal consequences. Warning of rotating parts This waming marker is used before activities during which there are risks due to rotating parts of the machine, possibly with fatal consequences. This warning marker is used before activities during which there are risks due to slipping, possibly with fatal consequences. Warning of tripping hazard | nis warning marker 1s used before activites dunng which there are nsks ‘due to tipping, possibly with fatal consequences. Warning of crushing hazard This warming marker is used before activities during which there are risks due to crushing, possibly with fatal consequences. Warning of crushing hazard This waming symbol is used for activities during which there are risks due to open belts or chains, possibly with fatal consequences, Warning of crushing hazard This waming sign is displayed for activities with a risk of crushing, Warning of crushing hazard This waming sign is displayed for activities with a risk of crushing. Warning of hot surface This waming marker is given before activities during which there are risks due to hot surfaces. 12/269 BAL_1011_2825145_00_en © Joseph Végele AG 2013,General Introduction ‘Warning of explosion, battery area This warning marker is given before activities during which there are risks ‘due to corrosive liquid and gases. ‘Warning of inflammable substances This warning marker is used before activities during which there are risks ‘due to inflammable substances, possibly with fatal consequences. ‘Warning of potentially explosive substances This warning marker is used before activities during which there are risks due to potentially explosive substances, possibly with fatal consequences. ‘Warning of toxic substances This warning marker is used before activities during which there are risks due to toxic substances, possibly with fatal consequences. Warning of falling hazard This warning marker is used before activities during which there are risks due to falling, possibly with fatal consequences. ‘Warning of high pressure nis warning marker 1s used before activites dunng which there are nsks ‘due to systems under pressure, possibly with fatal consequences. ‘Warning of laser beams ‘This warning sign is displayed for activities with a risk caused by laser beams. Warining - Risk of being buried This warning sign is displayed before activities with the risk of being burried. >PPPPDED | ‘Warning of trapping hazard This warning sign is used before activities during which there occur risks ‘due to rotating augers or conveyors, with possibly fatal consequences. © Joseph Vigele AG 2013, BAL_1011_2325145_00_en 13/269General Usage 1.01.05 6 Signal words ANGER Identifies immediate danger. If this danger is not avoided, fatality or very ‘serious injuries will be caused. Identifies a possibly dangerous situation. If this situation is not avoided, fatality or very serious injuries may be caused, Identifies a possibly dangerous situation. If it is not avoided, it can result In light or minor injury. 1.03 1.03.01 Documentation Usage Correct use A copy of these instructions must be available to the authorized Personnel during the entire service life of the machine. Ensure that these instructions are supplied together with the machine in case of a resale. ‘These instructions form a unity together with the operating instructions to be compiled by the operating organisation. Before you start using the machine, you must have read and understood these instructions. ‘These instructions are intended to familiarise you with basic tasks / activities on the machine. ‘These instructions cortain important instructions on the safe and correct, use of the machine. Observing the instructions will help: To prevent dangers. To reduce repair costs and downtimes. + To increase the reliability and service life of the machine. Irrespective of these instructions, the laws, regulations, directives and standards applicable in the country and place of use must be observed. ‘The usage of the machine is described in these instructions, ‘These operating instructions are only valid in conjunction with the safety manuals of Joseph Végele AG. The relevant safety manuals are given on page 247, A copy of this safety manual must be available to the operator of the machine at all times. ‘The state-of-the-art machine complies with the applicable safety regulations at the time it was placed on the market in the context of its correct use. Itwas not possible to prevent foreseeable misuse or residual hazards by design means without restricting correct functionality. 14/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013General Usage ‘The machine is designed: * For paving, compacting and smoothing construction materials used in layers for road surfaces. ‘The machine is only intended for industrial use on closed construction, sites. ‘The machine must be operated by trained operators in accordance with the requirements in the technical documentation. Any incorrect use and all activities on the machine that are not described in these instructions represent unauthorised misuse beyond the bounds. of the manufacture’s liability. 1.03.02 Reasonably foreseeable incorrect use If the machine is used incorrectly due to reasonably foreseeable misuse, the manufacturer's warranty is void and the operating organisation carries sole responsibility. Reasonably foresezable incorrect uses are: * Carrying people. * Leaving the operator's stand during operation. ‘= Placing in operation, operating the machine from outside the operator's stane. ‘+ Operating the machine with the floor folded up. ‘+ Spraying with high-pressure cleaners or fire extinguishing equipment. + Removal of safety devices. + Failure to observe maintenance intervals. + Failure to take measurements and perform tests for the early detection of damage. «Failure to replace wear parts, * Failure to perform maintenance and repair work. * Incorrectly performed maintenance and repair work. * Storage of objects in places within the machine which were not designed as stowage. 1.03.03 Residual hazards ‘The residual hazards were analysed and evaluated prior to the start of the design and planning for the machine. Existing residual hazards are identified in the documentation. ‘You can avoid existing residual hazards by implementing and ‘observing these requirements in practice: + The special wamings on the machine. ‘+ The general safety instructions in these instructions and in the safety manual. ‘+ The special wamings in these instructions. ‘The instructions in the safety manual. ‘+ The operating organisation's instructions on operation. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 15/269mr oi os Dangers that may result in fatality / injury can arise on the machine due to: + Incorrect use. + Incorrect operation + Transport. + Missing safety devices. + Faulty or damaged components. ‘= Operation / use by personnel who have not received training, instruction. + Noise emissions. Pollution can arise due to the machine in case of: * Incorrect operation. ‘= Escaping oils, greases or fuels (lubricants, etc.) Damage can be caused to the machine due to: * Incorrect operation, * Failure to observe operating and maintenance requirements. * Unsuitable oils, greases or fuels. Damage can be caused to other property in the area where the machine is operated due = Incorrect operation. Performance limitations or limitations on the functionality of the machine can arise due to: # Incorrect operation. * incorrect maintenance / repair or failure to perform maintenance / repair. ‘= Unsuitable oils, greases or fuels. 1.03.04 Climatic conditions Low ambient temperature In cold weather the start performance and the operation ofthe diesel ‘engine depends on the following * Used fuel * Engine oil viscosity + State of the battery 18/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013me General Disposal Pieces of advice for the operation in cold weather: * Allow the engine to run until the operating temperature has been reached. By reaching the right operating temperature, itis avoided that the inlet and exhaust valves get stuck * After shutting down the engine the cooling and lubrication systems are rot immediately cold. That means that the engine can be shut down for a few hours and afterward be restarted without problems. + Below 0°C (32°F) use winter fuel + Before the cold season starts, filn the lubricant recommended by the engine manufacturer. + Weekly check all parts (hoses, V-belts etc.) * Check all electrical cables and connections for chafe marks and damage at the insulation. + Keep the battery charged and warm, + Fill fuel tank at the end of every working shift. At special operating conditions different greases, oils and fuels have to be used. ‘Acceleration and braking performance are influenced by viscous hydraulic ol. At low outside temperatures wait a few minutes after starting the diesel engine until puling away. Run the machine only at low load during the warm-up phase until the oil ‘of the hydraulio eyctom hae heated up to approx. 20 °C (68 °F). High ambient temperature, high altitude ‘The maximum power of the engine, exhaust gas quality, temperature level and in extreme cases the starting characteristics can be impaired. IT the machine is operated at altitudes higher than 1,000m or above an “ambient temperature of 30 °C (86 °F), quantity of injected fuel is reduced ‘automatically. 1.04 Protection of the environment 1.05 Disposal Packaging, cleaning agents and waste or left-over greases, oils and fuels are to be recycled in accordance with the regulations on the protection of the environment applicable in the place of use. ‘The protection of natural resources is a priority task. Correct disposal will prevent negative effects on people and the environment and will make it possible to recycle valuable raw materials. Oils, greases and fuels lls, greases and fuels are to be disposed of in accordance with the ‘corresponding specifications and the related national regulations, Materials (metals, plastics) To be able to dispose of these materials correctly, they must be sorted by type. Clean other substances sticking to the materials. Dispose of materia’s in accordance with the related national regulations. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 17/269= oi = Electrics / electronics ‘The electrical / electronic components are not subject to the WEEE directive 2002/96/EC and the corresponding national laws (in Germany e.g. ElektroG). Send the electrical / electronic components directly to a specialist recycling organisation 18/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el General Declaration of conformity 1.06 Declaration of conformity C ‘The declaration of conformity is part of the documentation provided ‘separately by Vogele AG and will be handed over to you on the delivery of the machine. ‘The CE marking on the machine is part of the type plate. ‘The pictogram indicates conformity with the applicable EU directives that relate to the product — that is the machine — and which require a CE marking. It appiies to the combinations of road paver with screed fitted. EC Declaration of conformity In the context ofthe EC Machinery dectve Heorowith Joseph Végele AG ‘oseph- Vagele- St. 1 67075 Ludwigshafen - Germany octares thatthe rachine listed below comprising Description: Readpaver —and_—Descpion’ Seed Tipe Type Seon Series: Machine LD No, acne LD No. compiles with the flowing EC drectves including amendments. 2006 42/EC_ Machinery directive 2008 /108/EC EMC drectve 2000/14 Nols emission recive As per atte 12°, Annex 1 Procedure for assessing conformity in accordance with Annex VII" ‘Asperarice 13, Annex 1 Procedure for assessing conformity in accordance with Annex V Pewee rating! kw. ‘cund power level Lua measured (A), Scund power level Lua guaranteed: (A). Harmonised standards applied EN5004 Tobie road constructon machinery. — Safety (Part: Common requrements) EN 5006 Mable road constucton machinery. — Safty (Part 6: Speci requirements for paver fishers) EN 13309 _Constructon machinery. Electromagnetic compatity of ‘machines wth intemal eecrcal power supply erson authorised forthe compilation ofthe relevant technical documentation: le Klaus Oetings, Joseph Vigele AG, Joseph Vogele- St. 1 157075 Ludwigshafen, Germany “Noted boty Eepsich nttets Stale, Kern 0515 [GUY Tes Prt-und Zostera echborieh Bauwecon (Crebuper Sate 308 80667 anenen (Cemmary) Lcwganaten, Heed of covet anc etn “Trneaton oh ral EC detron of sony 7 © Joseph Végele AG 2013 BAL_1011_2325145_00_en 19/269General VOGELE| iene e le 1.07 Type plate Fig. 1-1: Type plate [1] Type plate [2] Side trim panel left [3] Side trim panel rear [4] LD. number All the information is of documentary value and is not allowed to be ‘changed or rendered ilegible. Enter the data on the type plate in the chart below: Designation Data 1. Series / type }2. Machine I.D No. [3. Year of manufacture [4. Output kWimin* 5. Output kWimin= [6. Admissible Axle [Front lRear 7. Admissible Total Weight [8. Operating weight [9. Max. operating weight Chart 1-1: Data on the type plate 20/269 BAL_1011_2325145_00_en (© Joseph Végele AG 20131.08 1.08.01 1.08.02 1.08.03 1.09 General Technical data Engine type plate Enter engine manufacturer, engine type and engine number in chart below: Design Data 1. Manufacturer 2. Engine type 3. Engine number Chart 1-2: Data on the engine type plate Noise and vibration figures ° 1 Itis not allowed to make any changes to the machine that will result in an increase in the noise emissions. + Wear your personal safety equipment (ear defenders) if necessary. Read and observe the safety manual. Ensure all safety devices are fitted and functional * Do not make any changes to the machine. Sound power level ‘The sound power level is given in the "Charts" section (see page 230). Determination and implementation as specified in EC Directive 2000/14/EG, EN ISO 3744 and EN 500-6. Sound pressure level The daily noise exposure level (Ly, a) Of 80 dB(A) may be exceeded ‘when working with the machine in the operator's stands. ‘= Wear your personal safety equipment (ear defenders) if necessary. Uncertainty of measurement in accordance with EN ISO 11201 Vibration information for the operator Whole body vibration If the machine is used correctly, the weighted effective values for the acceleration of whele body vibration at the operator's position and the ‘outer control stands of ay = 0.5 m/s* - in the context of EN 1032: 2003 - are not exceeded. Hand-arm vibration fused correctly, the weighted effective values for the acceleration of hand-arm vibration of ajy, = 2.5 m/s?- in the context of EN 1032: 2003 - are not exceeded. Technical data The technical data on the machine are given in the "Charts" section (see page 227). © Joseph Végele AG 2013 BAL_1011_2325145_00_en 21/269General Sere nd tgs 6 1.10 Personnel - qualifications and obligations Only authorised personnel are allowed to perform any activities on the machit The authorised personne! must: Be at least 18 years of age. ‘= Be trained in frst aid and be able to provide first aid, Have read and understood the safety manual. ‘Be familiar with and able to apply accident prevention regulations and ‘safety instructions for the machine. + Be appropriately trained and instructed on how to react malfunetion. ‘+ Have the physical and mental faculties to be able to perform his/her responsibilities, tasks and activities on the machine. ‘+ Be appropriately trained and instructed for his/her responsibilities, tasks and activities on the machine. + Have understood and be able to practically implement the technical documentation related to his/her responsibilities, tasks and activities, ‘on the machine. Prior to placing the machir + The operating instructions. © The safety manual. case ofa in operation, read: Itis only allowed to employ people to drive machines who also: ‘+ Have been instructed on driving the machine. + Have demonstrated their skills to the employer. + Can be expected to reliably tackle the tasks given to them. ‘They must be appointed by the employer / organisation to drive the machine. 22/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013General Personnel - qualifications and obligations Follow the instructions below: + Familiarise yoursetf with the equipment fitted to the machine. ‘+ Only drive the machine when you have fully familiarised yourself with the controls and method of operation. + Familiarise yourself with your working area. ‘+ Only use the machine for the purpose intended. ‘Use suitable lifting gear for transport and fitting heavy extensions or accessories. + Wear your safety equipment, for example safety shoes and ear defenders. ‘If defects are found on the safety devices, inform your supervisor without delay. © Ifother defects are found that compromise the safe operation of the machine, inform your supervisor without delay. + Incase of defects that endanger people, shut down the machine immediately. ‘+ Ifany conversions and changes to the machine impairing safe operation are detected, inform your supervisor immediately. * Ensure the machine is always in roadworthy condition ‘© Ensure the dates for regular safety inspections by authorised personnel are observed. ‘= Pay attention to the following items fastened to the machine: — Safety markings. — Markings for the protection of the health. — Safety instructions. + Read the additional safety regulations and instructions prepared by the operating organisation / employer for special situations. ‘+ Check the completeness and legibility of the = Safety markings. = Markings for the protection of the health. Safety instructions (signs, labels, pictograms).. + Prior to starting work, obtain information on. = First aid. — The emergency services (paramedios, fire brigade, helicopter). + Ensure a first aid box is available with the contents as required by the regulations. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 23/289General Sere nd tgs 6 1.10.01 Assistant Assistants are always required if the driver does not have adequate visibility of the road or path. Itis only allowed to employ people to assist machines who in addition: + Have been instructed on assisting (the machine). = Have demonstrated successful attendance at the training course. Have demonstrated their skills to the employer. + Can be expected to reliably tackle the tasks given to them. ‘They must be appointed by the operating organisation / employer to assist the road paver. To avoid misunderstandings, the unambiguous hand signals, e.g., in accordance with German BG regulation BGV A 8 on health and safety markings on the workplace should be used. Note the instructions below: ‘+ Familiarise yourself with the dimensions of the road paver and the low-loader. + Wear reflective clothing. + Assistance can be by radio (for example on loading using the crane) ‘or by hand signals (for example on reversing the road paver). ‘+ The meaning of the signals must be clarified beyond doubt between river and assistant. Service personnel The service personnel are responsible for ensuring that: + The safety markers and instructions on the machine are in legible ‘condition. ‘+ The machine is protected against unauthorized use during repairs and maintenance. Repairs are approved by the manufacturer. ‘+ The machine is only operated when itis fully functional and in correct ‘working order. Personal safety equipment All parts of the personal safety equipment must be worn during all, activities on the machine described in these instructions. This includes e.g.: + Safety shoes * Safety gloves = Eardefenders * Warning clothing Observe the regulations regarding personal safety equipment (e.g. hard hat) applicable in your country / region. 24/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013om cos a 1.11 General safety instructions 4.11.01 Safety manual Read the safety manual provided separately by Vagele AG. Itis a constituent part of the operating instructions. 1.11.02 _ Instructions on electrical / electronic components Please adhere to the following safety instructions for optional electrical / ‘electronic components: ‘+ Check the goods immediately on receipt for damage or defective parts, + Do not place faulty equipment in operation. + Damaged leads and connectors are a safety risk and must not be used under any circumstances. * Contact your VOGELE supplier who will provide a replacement immediately. Installation Prior to installation, operation and using the equipment, read the ‘operating instructions thoroughly and completely. If you have any questions, please contact your VOGELE supplier. Only the original VOGELE leads are allowed to be used for the installation of the equipment. The connectors are not allowed to be removed from the leads, as they are protected against moisture. Opening the connectors would destroy this protection. Ensure locking screws on the connectors are tight. You will find further installation instructions for the equipment and sensors in the separate data sheets and operating instructions. Ifyou do not adhere to the instructions listed above, VOGELE AG L_| cannot provide any warranty for the electrical / electronic equipment (accessories) ‘Safety precautions The safety precautions recommended here comply in principle with the directives on the installation and commissioning of electrical systems. ‘They can be applied to all applications in conjunction with VOGELE equipment. Wiring and cabling The wiring and cabling must be laid correctly in accordance with the requirements in these instructions. All supply leads and connection terminals must be appropriately dimensioned for the current to be carried. In addition, all connections are to be made in accordance with the applicable VDE regulations and the related national regulations. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 25/289General General safety instructions hte Immunity to interference ‘This equipment has been designed and tested for i Nevertheless, the mictoprocessor technology places a number of requirements on the installation. For this reason we draw your attention to the following installation features that could result in subsequent malfunctions if not observed: ‘+ Ensure the polarity of the connections is correct, * Do not exceed or drop below the specified voltage range. + Aprerequisite for correct operation is a good electrical connection between road paver and housing chassis of the individual ‘components. ‘* Only connect screened leads to earth at one end (equipment end). ‘= Do not supply any other equipment with the supply voltage from the ‘connection terminals. + Do not use spare terminals for other connections or equipment. Fuse Equipment is fitted with fuses that provide protection against short circuits. The supply voltages given in the technical data are not allowed to be exceeded. Configuration ‘The equipment has a facility for configuration by the user. On re- ‘configuration, the user must only re-configure the equipment to suit the situation in the system. In case of questions on operation and installation, please contact your VOGELE supplier. If the precautionary measures listed above are not observed, the ‘equipment or system may fail. Damage caused by the failure to ‘observe the precautionary measures listed above is excluded from the manufacturer's warranty. 28/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eo ct 1.12 Hazard area Fig. 1-2: Hazard area [1] Hazard area ‘There must be no persons in the machine's hazard area during paving and transport. ‘The hazard area is only allowed to be entered for maintenance and cleaning work if: * The machine is stationary and secure. + The work is performed by authorised personnel. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 271289Goneral Ge VWleas Labelling SS 1.12.01 Safety distance between working area and road traffic ri 8 1 = —~ g -2 a 8 8 Ze so i= Zs &5 Fig, 1-3: Safety distance between working area and road traffic [1] Road traffic [2] Working area ‘The safety distance between the working area and road traffic is to be maintained as per national regulations. In Germany the following applies: * Directives for securing road works (RSA) ‘+ Additional technical contract conditions and directives on securing road works (ZTV-SA 97) [3] + Decree on construction sites including the related "Rules for health and safety on construction sites" (RAB) [5] 1.13 Labelling 1.13.01 Labelling diagram You will find the labelling diagram in the spare parts catalogue. 1.13.02 Labels used This sub-section provides you with information on the special function of the labelling, Please refer to the Safety manual for the description of safety-relevant signs! First aid box 28/289 BAL_1011_2325145_00_en © Joseph Vigele AG 2013General Labelling Noise Lashing points on the machine Itis only allowed to use eyes marked in this way for lashing the machine (e.g. for transport on a low-loader). Lifting points on the machine Itis only allowed to use the eyes marked in this way for loading the machine (for example using a crane). Never lift the road paver at the screed. Instruction on towing 24V sockets. 24V headlight socket Beacon socket Instruction on towing Engine oil SP Use only engine oil with the allowed specification. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 29/269rs oi Diesel tank Only for machines with the letter "i" at the end of the type name. Use diese! with a sulphur content of less than 0,015 %. Pay attention to standards. Diesel tank Only for machines without the letter "” at the end of the type name. Use diesel with a sulphur content of less than 0,5 %. Pay attention to standards. Drain fuel Fill with hydraulic oil Special hazards and precautions if welding is necessary. ‘Welding work on the machine is only allowed to be performed by qualified personnel. Specified tension of the drive chain in the gearbox To tension / reduce the tension, adjust the tensioning bracket such that the drive chain can move. Excessively loose or taut drive chains will result in increased wear on the idler sprocket and drive bearings. Special greases Use only lubricants of the specified type in the lubrication unit. 30/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eo a oa ‘Tow point ram scale Auger height scale Fuse assignments Addresses of VOGELE after sales service SUR © Joseph Végele AG 2013 BAL_1011_2325145_00_en 31/289om 92/269el Description Chassis / safety devices 2 DESCRIPTION 7_| Pov atenton tote isructons nthe Safety manual fra acts The road paver assemblies are described in this section. tem numbers on assembly illustrations are marked in the text with round brackets (). tem numbers on ilustrations of specific parts are marked in the text with ‘square brackets ]. 2.01 Chassis / safety devices 7 5 6 2 4 Fig. 2-1: Safety devices of the road paver (1) Operating instructions and = (2) Trim panels (see page wamings (see page 33) 34) (3) Lighting / waming features (4) Safety devices (see page (see page 37) 39) (5) Steps (6) Chassis (Hand ral (8) Towing point Safety devices are fitted to the road paver to protect people and property. 2.01.01 Operating instructions and warnings ‘The labels (operating instructions and warnings) must be fitted to the road paver and be legible. The warnings fitted directly on the road paver must be observed, ‘An overview of the labelling is given in the spare parts catalogue. ‘The operating instructions and warnings are described in the section on Labels used (see page 28). © Joseph Végele AG 2013 BAL_1011_2325145_00_en 93/289soot om 2.01.02 Trim panels 3 4 Fig. 2-2: Trim panels ()) [1] Engine compartment cover [2] Bonnet [1 Side trim panel eft [4] Side trim panel rear 6 Fig. 2.3: Trim panels (i) [5] Side trim panel rear [6] Side trim panel right 34/269 BAL_1011_2325145_00_en © Joseph Vigele AG 2013ee Ge Description Chassis / safety devices Fig. 24: Trim panels (ll) IM] Stowage cover 18] Switch box cover [9] Oil supply maintenance flap [10] Bevelled edges [11] _Tirst aid box cover ‘The covers protect against heat, noise and moving parts. The covers must only be opened for maintenance. ‘The bonnet [2] provides protection against heat and noise. Itis held up by ‘a gas strut and lock ‘Trim panels and bennet are locked with square locks in closed position. ‘The maintenance flaps / covers can be lifted easily due to the bevelled edges [10]. ‘The trim panels must be locked in retracted state during transport. ‘These maintenance flaps / covers are locked using a guide and secured with square key locks. ‘* Bonnet [2] + Side trim panel rear [4], [5] ‘These maintenance flaps / covers are secured with square key locks. * Cover for stowage [7] + Oil supply maintenance flap [9] + First aid box cover [11] ‘Shut down engine before opening the trim panels / covers. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 95/289etn @ pri aie Locks and square key locks Fig. 2-5: Lock and square key lock [1] Lock ‘Square key lock [I] Notches Opened side trim panels must be secured against closing with a lock [1]. ‘When the square key locks are closed, the notches [3] must be aligned. 96/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Description Chassis / safety devices 2.01.03 Lighting / warning features 2 3 1 4 Fig. 2-6: Lighting ana waming features [1] Hom [2] Halogen headlights [1 Floodlights [4] Warning light ‘The warning light [4] on the outer control stand flashes as soon as the sscreed's left or right extending unit is extended or retracted. The floodlights (option) [3] are fitted to the rail to illuminate the auger ‘compartment. ‘An audible waming signal, which sounds when the road paver reverses, is optionally available. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 37/289etn @ pri aie Beacons (option) Fig. 2-7: Beacons [1] Roof Beacon As an option a beacon [2] is available. It is fitted at the rear left on the roof, The electical connection is made on the rear wall of lie chassis. There are areas around the machine which are hard or impossible for you to see. Stop the machine immediately if anyone enters the hazard area or if you approach anyone with the machine. 38/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el 2.01.04 Safety devices Description Chassis / safety devices Fig. 2-8: Safety devices on the road paver 1 (3) 65) m1 ‘Screed locking pins Roof locking pins Roof Push roller safety chain 2 4 16] Foot lever for locking the driver's seat ‘Awning lock Hopper wall safety chain During transport the push rollers [7], the hopper walls [6], the screed [1], the roof [3], the driver's seats [2] and awnings [4] (retracted) must be locked. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 39/289Description & as Chassis / safety devices 2.01.05 Chassis Ventilation system Fig. 2-9: Air intake duct ofthe ventilation system [1] Connecting hose [2] Exhaust pipe Fig. 2-10: Air slots at the conveyor compartment BI Airsiot [4] Conveyor compartment 40/269 BAL_1011_2325145_00_en © Joseph Végele AG 2013a ce Description Chassis / safety devices ‘The ventilation system draws bitumen fumes from the auger ‘compartment. ‘The ventilation system comprises a hydraulically driven fan, a connecting hose [1] and an exhaust pipe [2]. Fumes from the auger compartment exit through the exhaust pipe [2]. Fine asphalt particles can settle in the ventilation system's air intake duct over time. 2.01.06 Space for fire extinguisher Fig. 2-11: Space for fre extinguisher [1] Space for fire extinguisher A space is provided on the hand rail [1], where a fire extinguisher can be attached if requires. National and/or local regulations regarding fire protection must always be ‘observed and a fire extinguisher must be retrofitted, if required. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 41/289ote @ oti 2.02 Operator's stand Fig. 2-12: Operator's stand of the road paver (1) Operator's console (see (2)'__Vandalism protection (see page 43) page 68) (5) Seat console win ralis (see (6) Outer control stana, (screea) page 69) (see page 71) (7) Roof (see page 96) (13) Operating instructions / first-aid box storage compartment ‘The operator's stand is the command centre and the operator's ‘workplace. All road paver and screed functions are controlled from the operator's stand. The storage compartment for the operating instructions / first-aid box (13) is below the driver's seat on the right. 42/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el 2.02.01 Operator's console Operator's console with mounting Description Operator's stand Fig. 2-13: Operator's console with mounting [1] Foot lever for tit adjustment [3] Locking leverfor sliding [4] [5] Guide rail [8] [7] Pivot locking lever to the left Pivoting locking lever to the righthand side Ignition key Cable duct If the locking lever [3] is pressed forward, the operator's console can be slid along the guide rail (5). For pivoting to the left, pull locking lever [7] to the stop. For pivoting to the Fight, pull locking lever [2] to the stop. The inclination of the operator's console can be adjusted by pressing the foot pedal for tilt adjustment [1]. Ignition key [4] Preconditior The ignition key switches the road paver's power supply on and off. Position 0 - isolates the road paver electrically. 1@ engine is switched off. Ifthe ignition key is set to 0 ‘while the engine is running, the engine continues running. * Position 1 - activates the control voltage for engine, control electrics and lighting. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 43/289ote @ oti Overview of operator's console Fig. 2-14: Overview of operator's console [8] Screed functions (middle) [9] _ Material conveying and propulsion (left) [10] Instruction label- Wear ear [11] Display unit defenders [12] Material hopper and steering (right) General button functions Buttons with arrows ‘The action of this control is retaining / momentary. When the buttons are released, ‘= The related unit remains in its actual position or ‘The actual steering angle is retained. Buttons for switching on and off ‘The action of this control is momentary. When the buttons are released, ‘+ The related unit remains in its actual position or + The related unit steps. Buttons with light emitting diode The light emitting diode in the buttons is lit if ‘= The function is switched on or ‘= The automatic moce is activated. 44/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013a Description Operators stand ‘Operator's console for material conveying and propulsion (left) Fig. 2-13: Operators console for material conveying and propulsion (len) [1] Main drive switen [2] Right distribution auger [3] Leftdistribution auger [4] Right conveyor [5] Left conveyor 18] Distribution auger height adjustment [10] Emergency stop [11] Reversing conveyors, [12] Automatic filing [14] Conveyors / distribution augers / tamper [15] Reversing crawler tracks [17] Control knob for paving speed [19] AutoSet [20] Operating mode selector switch F Main drive switch [1] ‘The road paver's direction of travel is selected: * Switch position (F) - drive forward (®) * Switch position Ry - drive backward | * Switch position (P) - stop (park position) R © Joseph Végele AG 2013 BAL_1011_2325145_00_en 45/289ote @ re In the manoeuvring and positioning operating modes, the main drive ‘switch also regulates the road speed ‘= Switch position (F)- drive forward — To move forward, release lock (A) by pulling up and move main drive switch forward. — Paving operating mode: The road paver moves continuously forward, according to the speed range set using the control knob for paving speed. The speed range must have been set with the control knob [17] for paving speed. — Manoeuvring ard positioning operating mode: Road paver moves forward without steps if the main drive switch is pressed forward. ‘+ Switch position (R)- drive backward — To move backward, release lock (A) by pulling up and move main drive switch backward. — Manoeuvring ard positioning operating mode: Road paver moves backward without steps if the main drive switch is pressed backward. * Switch position (P)- stop = The parking brake is activated. Advance drive pumps on the advance drive are switched off. ~The automated grade and slope control is switched off. — Conveyor and compaction systems in automatic mode are switched off. mle ~vikAA Right distribution auger The button has the following functions: ‘= Left button: Automatic mode is switched on or off. ‘= Right button: = Right distribution auger is switched on or off in manual mode. = The actual speed is overridden in the automatic mode The button for the left distribution auger [3] functions likewise. Right conveyor [4] The button has the following functions: ‘Top button: Automatic mode is switched on or off. ‘= Bottom button: — Right conveyor 's switched on or off in manual mode. — The actual speed is overridden in the automatic mode. The button for the left conveyor [5] functions likewise. 46/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013a ce Description Operator's stand Distribution auger height adjustment [8] (Option) The button has the following functions: * Top button: The distribution auger is raised * Bottom button: The distribution auger is lowered. Emergency stop [10] The diesel engine, all units and the screed are shut down when the ‘emergency stop button is actuated. ‘The emergency stcp remains active until the emergency stop button, ‘hich tripped, is reset manually. There are three emergency stop buttons ‘on the machine (operator's console and outer control stands). To reset the emergency stop, tum emergency stop button clockwise. All functions on the road paver must be switched off so that you can re~ start the road paver (main drive switch set to P) O &®: > Reversing conveyors [11] Both conveyors reverse at moderate speed. Automatic filling [12] Conveyors and distribution augers are switched on and controlled via ‘sensors (paddle control or ultrasonic sensor). Conveyors / distribution augers / tamper [14] Conveyors, distribution augers and tamper are switched ON or OFF. Conveyors, distribution augers and tamper run at moderate velocity or ‘speed with this function. This button is used to warm up the road paver and to clean these units. Reversing crawler tracks [15] Precondition: + Main drive switch [1] is in position P. The crawler tracks of the road paver run in opposite directions as a function of the position of the steering joystick [51]. Using this function the road paver can be turned on the spot. The action of this control is retaining / momentary. When its released, movements of the steering joystick [51] will have no effect. e = OO! © Joseph Végele AG 2013 BAL_1011_2325145_00_en 47/289Description Operator's star nd Control knob for paving speed [17] ‘The control knob continuously regulates the road paver's paving speed. * Precondition: Operating mode selector switch [20] is in paving position, Autoset [19] ‘Autoset function. The machine is prepared for transport in manoeuvring / positioning mode or, after manoeuvring, is prepared for paving in paving mode. The Autoset function includes: * Raising / lowering the screed ‘= Raise / lower distribution auger (to the selected mechanical end stop) Raising / lowering material strike-off plates * Raising / lowering the entry flap ‘+ Reversing the conveyor (in manoeuvring / positioning mode) Operating mode selector switch [20] ‘The road paver operating mode is selected: ‘Transport + Neutral + Manoeuvring + Positioning = Paving ‘You select the operating modes using the arrow buttons. Once an operating mode has been selected, the related light emitting diode illuminates. 48/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013le Description Operator's stand ‘The functions are enabled and adapted to suit the related operating mode. Transport — All automatic functions are inactive. Neutral Diesel engine warms up. = Screed warms up. All drives are disabled except diesel engine and screed heating, — The road paver cannot be moved. + Manoeuvring ~ Manoeuvring on the construction site, = All automatic functions are inactive. * Positioning = Sensitive driving, e.g. for moving the road paver to a new starting position. — Road paver reacts exactly to movements of the steering joystick. — Allautomatic functions are inactive. + Paving = Lays the mixon the pre-base. All functions and screed float are active. = Retrofitting is not possible. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 49/289Description & VOGELE| Operators stand Operator's console for screed functions (middle) 33 34 35 30 38 Fig 2-46 Operatnrts ennsnle far srreed fuinetinns (mite) [30] Left extending unit [31] Screed heating [33] Left tow point ram [34] Raising / lowering, locking screed [35] Right tow point ram [37] Screed assist (option) [88] | Right extending unit ‘Screed heating [31] Screed heating is switched ON or OFF. © Diode illuminated: Screed heating has been switched on. $= Left tow point ram [33] ‘The button has the following functions: ‘+ Top button: Left screed tow point ram is raised, ‘= Bottom button: Left screed tow point ram is lowered, The button for the right tow point ram [35] functions likewise, mie 50/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013a ce Description Operator's stand + Raising / lowering screed [34] (option) SSS The button has the following functions: + Top button: Function not used. + Middle button: The screed is raised. + Bottom button: The screed is lowered mu it) y) } Screed assist [37] (option) > screed assist is switched ON or OFF. i The screed assist is only active with screed float. S_CsRightextending unit (38) The button has the following functions: + Right button: The ight ecreed extending units extended. + Left button: The right coreed extending unit ie retracted. ‘The button for the left extending unit [30] functions likewise. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 81/289Description Operator's stand om Operator's console for material hopper and steering (right) Fig 2-47: Opeminis enraele far material hopper and stearing (righ!) (st) (53) 155] 17 (61) (67) [63] Steering joystick 52) Adjusting dieselspeed [54] Beacon (option) 01 Not used 9) Raise / lower material [66] deflector (option) Moving the right hopper wall [68] Move left hopper wall ee — Storing joystick [51] ‘The road paver is steered using the steering joystick. bes* Hom [52] O An acoustic waming signal is sounded when pressed. Hom Starting / shutting down engine Lighting ‘Steering trimming Not used Raising / lowering hopper walls / entry flap 52/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Description Operator's stand Adjusting diesel speed [53] * MAX - maximum production rate Usage: Paving and heating + ECO - reduced fuel consumption and wear (reduced production rate) Usage: Paving and heating * MIN -idle operation Usage: Heating ‘You can select the diesel speed using these buttons. Once a diesel speed has been selected, the related light emitting diode illuminates. If automatic diesel speed adjustment is active, the diode flashes. START/STOP Starting / shutting down engine [54] + Starting the engine: Never keep button pressed for more than 10 seconds. If the button is pressed for more than 30 seconds wait at least 2 minutes before re-starting the road paver. + Shut down the engine: Keep button pressed for more than one ‘second. Press the Start / stop engine button only when the Preheat symbol has ‘gone out. Beacon [55] (option) The 24 V socket for the beacon is switched ON or OFF. Oo =D Lighting [56] Lighting and the 24 V sockets to which parts of the lighting are connected are switched ON or OFF. @ ‘Steering trimming [59] The button has the following functions: « mp Left button: Road paver steers continuously to the left. + Middle button: Road paver moves straight ahead. + Right button: Road paver steers continuously to the right. Long bends can be driven around with the aid of the steering trimming. ‘The steering trimming is used as a fine steering regulator and keeps ‘exactly to the radius of the bend. In this way it is possible to drive evenly ‘and continuously around bends. Precondition: Paving operating mode Is active. Bm, Ralsing lowering sereed [61] The material deflector is raised / lowered. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 53/289ote @ re DA) Move right hopper wall [67] The button has the following functions: + Top button: The right hopper wall is raised. ‘* Bottom button: Right hopper wall is lowered. The button for the left hopper wall [69] functions likewise. hale fig) Raising | lowering hopper walls / entry flap (option) [68] ‘The button has the following functions: ‘+ Top button: Both hopper walls and the entry flap (option) are raised. * Bottom button: Both hopper walls and the entry flap (option) are lowered. Display unit Rots Fig. 2-18: Display unit [80] Soft keys [81] Display [82] Malfunction indicator [83] Brightness sensors for display. [84] Navigation block 54/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Description Operator's stand Soft keys [80] ‘The symbols shown on the display define the current function of the soft keys. ‘The soft keys have the following functions: ‘+ Functions are switched on or off ‘Fields are activated for the entry of values Malfunetion indicator [82] Flashes if there is a malfunction on the road paver. Brightness sensors for display [83] ~ Adjusts the brightness of the display. Navigation block [84] Using the navigation block you can change values, activate or deactivate functions and navigate on the display pages. ‘The navigation block has the following functions: + ESC button: = Change to higher level display pages = Discard values + Return button: — Save values * Arrow buttons: = Leaf through the display pages = Increasing or reducing values © Joseph Vigele AG 2013 BAL_1011_2325145_00_en 85/289Description Ge VWleas Operator's stand SS Start pages Fig, 2-19: Start page ()) Sub-menu tor [1] Distribution augers [4] Material sensor position, left conveyor Conveyors [5] Paving speed / driving ‘mode indication B] Screed [6] Material sensor position, right conveyor [7] Tamper [11] Steering trimming [8] Vibration [12] Preheat status display [10] Information on the road paver [13] Malfunctions Miscellaneous [9] Page number [14] Time ‘The steering trimming indication [11] indicates the steering angle. The steering trimming is only active in the paving operating mode. ‘The soft keys to [1], (2), (3), (7] (8), [10], [13] call up the respective sub- menu. 56/269 BAL_1011_2325145_00_en © Joseph Vigele AG 2013Operator's stand Fig. 2-20: Start page (M) ‘Sub-menu [15] Service related section [18] AutoSet [16] Screed heating temperature [19] Brightness regulation [17] Automatic diesel speed adjustment ‘The sub-menu items [15]-19] open the related sub-menu. © Joseph Vigele AG 2013, BAL_1011_2325145_00_en 87/289Description Ge VWleas Operator's stand SS Malfunctions sub-menu 9 ee ao n Fig. 2.21: Malfunctions sub-menu 1 BI) (5) a Pp) a1 If there is a malfunction in the road paver, Overfiow oil fter clogged Runback suction filter clogged High coolant temperature Fuel low Low engine oil pressure Engine fauit / engine warning ica) [4] [6] (8) 10) 2) Emergency stop triggered Air fiter clogged Low coolant level, Full water trap Alternator or D+ malfunction Engine fault / Stop diesel engine + The malfunction indicator (82] on the display unit flashes. ‘+ The related symbol for the malfunction appears on the display. 58/289 BAL_1011_2325145_00_en © Joseph Vigele AG 2013Description Operator's stand Distribution augers sub-menu Fig, 2-22: Distribution augers sub-menu [1] Reversing ON / OFF [21 Switching on or off reversing indication ‘Symbols / indications on the left relate to the left distribution auger. The behaviour on the right is similar. Conveyors sub-menu Fig. 2-23: Conveyors sub-menu [1] Indication of rate setpoint (in [2] Entry of rate percent of the max. material flow regulation) ‘Symbols / indications on the left relate to the left conveyor. The behaviour con the right is similar. © Joseph Vogele AG 2013 BAL_1011_2325145_00_en 59/268,Description Ge VWleas Operator's stand SS Screed sub-menu Fig, 2-24: Screed sub-menu [1] Switching on oroffscreed [2] Screed freeze ON / OFF freeze indication IB] Screed float lock [4] Screed float ON / OFF indication ‘Screed floal lock [3] is only active if the soft key is pressed. 60/269 BAL_1011_2325145_00_en © Joseph Vigele AG 2013‘Tamper sub-menu Fig. 2-25: Tamper sub-menu [1] Switching on or off “Manual” [2] "Manual" operating mode operating mode ON / OFF indication [3] Switching on or off [4] “Automatic” operating mode ‘Automatic operating mode ON / OFF indication [5] Tamper speed entry 16] Tamper speed setpoint indication © Joseph Vigele AG 2013, BAL_1011_2325145_00_en 61/289Description Ge VWleas Operator's stand SS Vibration sub-menu Fig. 2-26: Vibration sub-menu [1] Switching on or off "Manual" [2] "Manual" operating mode operating mode ON / OFF indication [3] Switching on or off [4] “Automatic” operating mode ‘Automatic operating mode ON / OFF indication {51 Vibration speed entry [6] Vibration speed setpoint indication 62/269 BAL_1011_2325145_00_en © Joseph Vigele AG 2013Description Operator's stand ‘Sub-menu with information on the road paver Fig, 2-27: Sub-menu with information on the road paver m1 B) 1 m Preheat status display Changing state of battery Engine speed Paving distance counter Resetting the paving Engine coolant temperature Operating hours counter Fuel contents ‘The pieces of information on the road paver are read in rows. ‘The paving distance counter [7] is an approximate figure. Depending on the slip between the tracks or wheels and the surface, the paving distance counter [7] may vary significantly from the actual distance covered. © Joseph Vigele AG 2013 BAL_1011_2325145_00_en 63/289Description Ge VWleas Operator's stand SS Fig, 2-26: Screed heating temperature regulation sub-menu [1] Indication of screed sockets [2] Screed pulsing ON /OFF (ON (green) / OFF (grey) IB] Screed pulsing ON/OFF [4] _ Screed heating temperature indication regulation ON /OFF [51 Screed heatingON/OFF [6] _ Input of screed heating indication temperature (option) [7] Display of screed heating [8] _ Screed plate temperature temperature setpoint (option) _inication (option) 64/269 BAL_1011_2325145_00_en © Joseph Vigele AG 2013Automatic diesel speed adjustment sub-menu Fig. 2-29: Automatic diesel speed adjustment sub-menu [1] Automatic diesel speed [2] Automatic diesel speed adjustment ON / OFF adjustment ON / OFF indication ‘The automatic diesel speed adjustment is coupled to the main drive switeh [1] Ifthe automatic diesel speed adjustment is switched on, the road paver runs at the pre-set diesel speed (MIN, ECO, MAX) after the main drive switch [1] is deflected © Joseph Vigele AG 2013, BAL_1011_2325145_00_en 65/289oa oi Fig. 2-30; AutoSet submenu [1] Screed ON / OFF indication [2] Raising / lowering the screed [3] Distribution auger ON / OFF [4] _ Raising / lowering the indication distribution auger [5] Raising / lowering material [6] Material deflector ON / OFT deflectors indicator [7] Raising / lowering the entry [8] __ Entry flap ON/OFF flap indication [9] Reversing conveyor ON/ [10] _ Reversing conveyor ON / OFF OFF indication [11] AutoSet data storage When running AutoSet function in manoeuvring / positioning mode, the ‘components (e.g. material deflector, screed) selected in the AutoSet ‘sub-menu are set to transport position, and in paving mode to the latest position saved in the memory. ‘When running the AutoSet function, the AutoSet sub-menu is displayed automatically. The fields [1], [3], [6], [8], [10] indicate whether the related function has been fully completed. ‘The components (e.g. material deflector) can be selected individually. ‘The component raise / lower screed [2] is always active. The lowered position of the distribution auger can be defined by a mechanical lock. 66/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013a ce Description Operator's stand Brightness sub-menu (display) [An FT FT | Fig. 2-31: Brightness sub-menu (display) [1] Switch on oroff brightness [2] Brightness value indication adjustment cisplay © Joseph Végele AG 2013 BAL_1011_2325145_00_en 67/289sce em Operator's stand 2.02.02 Vandalism protection Fig. 2-32: Vandalism protection [1] Vandalism protection The vandalism protection (2) protects the operator's console (1) against ‘wanton damage and the road paver against unauthorised use. Ifthe vandalism protection (2) is not required, it can be hung on the left- hand seat console and locked. ‘There are concise instructions in the vandalism protection (2). The instructions are placed on the operator's console and show all the steps. necessary to be able to drive the road paver, e.g. during loading. 68/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013a ce Description Operator’ stand 2.02.05 _ Driver's seat with rails » a — Fig. 2-33: Drivers seat, standard [1] Footleverforlocking the [2] Adjusting the height Uhiver's seat [3] Folding the backrest [4] Sliding the driver's seat to the front / rear [5] Adjusting the body weight © Joseph Végele AG 2013 BAL_1011_2325145_00_en 69/289ote @ re Fig. 2-34: Driver's seat, deluxe [1] Foot lever for locking the ‘Adjusting horizontally driver's seat TB] Adjusting the body weight [4] Removable head rast [51 Adjusting the folding armrest [6] Adjusting seat position 7] Adjusting seat position [8] _Height adjustment [8] Switching on seat heating The control elements of the driver's seat depend on the design of the seat. By actuating the foot lever for locking the driver's seat [1], the carrier of the driver's seat is unlatched. The driver's seat (2) can be pivoted outward. Seat heating is switched on and off using a switch on the driver's seat. i The driver's seat pedal [1] must engage again after adjustment of the, seat. 70/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013ee Ge Description Operator’ stand 2.02.06 Outer control stand Fig. 2-35: Outer control stand [1] Button unit [2] Display unit [3] Emergency stop [4] Warning light [5] Machine connection [6] Connection for NIVELTRONIC Plus® tow Point sensor (option) [7] Material sensor connection [8] Mounting [8] Working area light Except the tow point rams, the left and right-hand side functions of the ‘wo outer control stands (3) are separated. The outer control siands (3) are stored in a separate case ‘As an option a levelling unit NIVELTRONIC Plus® is available; this unit is integrated into the outer control stands (3). ‘The outer control siands (3) are firmly assigned to the related machine. Outer control stands are not intended to be exchanged between different road pavers since this can cause malfunctions. ‘Warning light [4] The left warning light flashes as soon as the screed's left extending unit is being extended or retracted. The same applies to the right warming light. Mounting [8] Is fitted to the bracket on the screed's end plate. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 711289ote @ re Button unit [1] 100 101 A ra an 402 sco BE a 404 108 —~__ | = a — 8ea 106 Fig. 2-36: Button unit on the outer control stand [100] Emergency stop [104] Distribution auger [102] Distribution auger height [103] Crown adjustment (option) adjustment (option) [104] Horn [105] Right tow point ram [106] Extending unit of the screed [107] Left tow point ram (smart whee!) [108] Screed float [109] Conveyor The outer control stand mounted on the right is described in the following. ‘The outer control stand mounted on the left functions likewise. Emergency stop [100] The diesel engine, all units and the screed are shut down when the ‘emergency stop button is actuated. ‘The emergency stop remains active until the emergency stop button, which tripped, is reset manually. There are three emergency stop buttons ‘on the machine (operator's console and outer control stands) To reset the emergency stop, tum emergency stop button clockwise. ‘All functions on the road paver must be switched off so that you can re- start the road paver (main drive switch set to ). 72/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Description Operator's stand @ : Distribution auger [101] The button has the following functions: * Button +/-: Set speed. + Top button: Automatic mode is switched on or off. ‘+ Left button: Distibution auger reverses at moderate speed. + Right button: = Distribution auger runs at maximum speed. = The actual speed is overridden in the automatic mode. + am = edi e: 8 ap: S Distribution auger height adjustment [102] (option) The button has the following functions: ‘+ Top button: The distribution auger is raised. * Bottom button: The distribution auger is lowered. Crown adjustment [103] (option) The button has the following functions: ‘© Right button: Increasing the setpoint * Left button: Reducing setpoint Horn [104] An acoustic warning signal is sounded when pressed. Right tow point ram [105] The button has the following functions: + NIVELTRONIC Plus® inactive — Top button: right-hand side screed tow point ram is raised, ~ Bottom button: right-hand side screed tow point ram is lowered. ‘+ NIVELTRONIC Plus® active — Top button: The setpoint for the right-hand side tow point sensor is increased. — Bottom button: The setpoint for the right-hand side tow point sensor is recuced. The button for the left tow point ram [107] functions likewise. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 73/289soa om Ss _Extonding unit ofthe screed (smart wheel) [106] ‘The controller has the following functions: * Controller to the right: The screed extending unit is moved to the right. * Controller to the left: The screed extending unit is moved to the left. ‘Screed float [108] If the button is kept pressed during paving, positioning and manoeuvring, ‘screed float is active. Ifthe button is released, the screed stops and remains in the current position. NOTICE Risk of damage to the machine Incorrect use of the "Screed float" button may result in damage to the ‘screed and/or the hydraulic system, If the "Screed float” button is used to lower the raised screed, the following situations may result: — The screed may fall down and be damaged - Air may enter the hydraulic system and affect its performance ‘© The "Screen float" button should only be actuated with the screed in lowered position, © In order to lower the screed, only use the "Lowering screed” button on the main operator's console. ©—® Conveyor [109] The button has the following functions: Q))) ~ Top button: Automatic mode is switched on or oft * Bottom button: CH) = Conveyor runs at maximum speed. — The actual speed is overridden in the automatic mode. 74/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Display unit [8] Description Operator's stand Fig. 2-37: Display unt on the outer control stand a BI io) ™ Soft keys fa LED cross ferthe left side [4] Brightness sensor for display [6] NIVELTRONIC Plus® on the [8] right side ON / OFF NIVELTRONIC Plus® on the laff side ON J OFF Display LED cross for the right side Navigation block Soft keys [11 TBI The soft key functions match the symbols shown on the display. NIVELTRONIC Plus® on the left side ON / OFF [2] NIVELTRONIC Plus? on the left side is switched on or off. The green light ‘emitting diode flashes if the screed is not in float position (machine not released). With NIVELTRONIC Plus® switched on, the green light emitting diode illuminates. ‘The button for the NIVELTRONIC Plus® on the right side [6] functions likewise. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 75/289Description Operator's stand ~ LED cross for the left side [3] om Indicates whether there is an error on the left NIVELTRONIC Plus® and in which direction it is necessary to correct, ifthe ACTUAL value is outside the working range. Indicator Description Significance ©e 9? | TOPLEDS illuminate (arrow |The ACTUAL value is too '@ 0° |downward) and bottom {high and must be corrected ©0409 0} EDs fash, downwards, he * e * 3 [Bottom LEDs ituminate [The ACTUAL value is too ae ae _ | arrow upward) and upper low and must be corrected ° eer O O|LEDs fash. lupwards. Chart 2-1: NIVELTRONIC Plus® LED cross likewise. Display [4] Brightness sensor for display [5] Adjusts the brightness of the display. Navigation block [8] Using the navigation block you can change values, activate or deactivate functions and navigate on the display pages. ‘The navigation block has the following functions: ‘+ Button up (display switch over): — Change between NIVELTRONIC Plus® start page and a display Page. me Page (see page 64), * ESC button: — Change to higher level display pages = Discard values * Arrow buttons: — Leaf through the display pages Display pages ‘The display has the following pages: + NIVELTRONIC Plus® * Machine i ‘The LED cross for the NIVELTRONIC Plus® on the right side [5] functions ‘The road paver, screed and NIVELTRONIC Plus® (option) functions are ‘shown on the display. If NIVELTRONIC Plus® (option) is not active, the display switch over ‘changes between the brightness display page and a machine display 78/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Description Operator's stand ‘Start page NIVELTRONIC Plus® (Option) =e Fig. 2-38: NIVELTRONIC Plus® start page NIVELTRONIC Plus® left-hand NIVELTRONIC Plus® right-hand side side [2] Tow point sensor selection _[10] Tow point sensor setpoint [3] Quick adjustment [14] Actual tow point sensor value [4] Automated grade and slope [12] Tow point sensor type (here control sensitivity ultrasonic wide range sensor in ground mode) [13] Automated grade and slope control sensitivity [5] Tow point sensor type (here ultrasonic wide range sensor in string line mode) [6] Actual tow point sensor value [7] Tow point sensor setpoint 114] Quick adjustment 115] Tow point sensor selection General [1] Open NIVELTRONIC Plus? parameters [8] Screed assist status display ON/OFF (here ON) ‘The NIVELTRONIC Plus® start page is displayed ifthe ignition is switched on and the NIVELTRONIC Plus® (option) is activated. The tilt sensor can be selected for the left or right side of the road paver. [9] Transverse slope Using the quick adjustment [3], [14] the setpoint for the sensors are adjusted to the actual value, which now becomes the new setpoint, © Joseph Végele AG 2013 BAL_1011_2325145_00_en 771289ste em Operator's stand ‘Symbols for the tow point sensors ‘Connection Description Road Outer control stand paver con- (left and right) nection Mechanical height sensor + aU ma’ : | Utrasonie wide range sensor for a) TPE.) |orouna string tne mode Mechanical wide range sensor for AL 6B {around rstring tine mode 1 (Chart 2-2: Symbols for the tow point sensors In the following you wil find menus in which you can change settings. me] NIVELTRONIC Plus" parameters (option) . Wa Fig, 2-39: NIVELTRONIC Plus® parameters [1] Open NIVELTRONIC Plus® [2] Open NIVELTRONIC Plus® sensor calibration sensitivity [3] Open expanded parameters [4] Open brightness settings 78/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eo a NIVELTRONIC Plus® sensor calibration (option) Fig. 2-40: NIVELTRONIC Plus® sensor calibration NIVELTRONIC Plus® left-hand —_NIVELTRONIC Plus® right-hand side side [1] Increase value [4] Increase value [2] Reduce value Ip] Reduce value General [3] Sensor indicator The increasing / reducing actual sensor value symbols [1}12], [4-15] set the actual value to the variable measured. ‘The displayed value must be compared with the actually measured value for calibration. In case of a deviation, the set value is adjusted to the measured value using the +/- buttons. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 79/289, & VOGELE| Operator's stand NIVELTRONIC Plus® sensitivity (option) Fig. 2-41: NIVELTRONIC Plus® sensitivity NIVELTRONIC Plus*left-hand _NIVELTRONIC Plus® right-hand side side [1] Increasing sensitivity [4] Sensitivity indication [2] Reducing sensitivity 15] Increasing sensitivity [3] Sensitivity indication [6] Reducing sensitivity If the value for the sensitivity indications [3], [4] is low, the response time of the units slows down. 80/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eo a Brightness adjustment (display) Fig. 2-42: Brightness adjustment (display) [1] Brightness value indication [2] _ Increasing brightness [3] Reducing brightness © Joseph Végele AG 2013 BAL_1011_2325145_00_en 81/289Description & VOGELE| Operator's stand NIVELTRONIC Plus® extended parameters (option) Fig. 2-43: NIVELTRONIC Plus® expanded parameters [1] Switching over fo one-sided [2] Open operation and alarm or double sided operation window of the levelling unit [3] Operating window sensor [4] _ Indication of single/double- symbol sided operation (here double-sided) [5] One-sided operation [6] Expanded parameters. indication symbol As required, you can change between one-sided and double-sided ‘operation using button [1]. 82/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eo a ‘Tow point operating window Fig. 2-44: Grade and slope control system operation and alarm window NIVELTRONIC Plus® left-hand —_NIVELTRONIC Plus® right-hand side side [1] Increasing the working range [4] Working range indication [2] Reducing the working range [9] Increasing the working range [3] Working range indication [6] Reducing the working range The initial working range is set to 2.50 cm ex factory. As soon as the ignition is switched on, this range can be set using the +/- buttons. Ifyou leave this pre-set working range, the NIVELTRONIC Plus? is inhibited. ‘When the engine is shut down, the setting returns to the pre-set value. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 83/289ote @ re Machine pages [I] Tre Diseay switch overbutton can be used to change rom leveling start age over to machine page and vice versa. Using the soft keys F1 and F5 you can change to the next or previous page. After the last page, the first page is displayed. Percentages on the pages always relate to the maximum value. Layout of machine pages Fig. 2-45: Layout of machine pages (example: tamper) [1] Select Manual mode ON/ —[2]_Select Automatic mode ON / OFF OFF, [3] Automatic operating mode [4] Manual operating mode ON / (ON / OFF indicator (here OFF indicator (here OFF) OFF) [5] Screed assist status display [6] Screed float ON indication ON/OFF (here ON) [7] Screed float OFF indication [8] __ Page symbol (here tamper) [8] Increasing the setpoint [10] Reducing setpoint The indications + Screed assist status indication [5] * Screed float position indication ON [6] * Screed float position indication OFF [7] are used repeating. The following menus indicate fictitious values. me 84/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Description Operator's stand Fig. 2-46: Tamper page iO) Select Manual mode ON/ [2] OFF Select Automatic mode ON / OFF [3] Automatic operating mode [4] _ Manual operating mode ON / ON / OFF indicator (here OFF indicator (here OFF) OFF) [5] Tamper speed setpoint [6] _ Increasing the setpoint T7]__ Reducing setpoint © Joseph Vigele AG 2013 BAL_1011_2325145_00_en 85/268Description Operator's stand Vibration page (option) Fig. 2-47: Vibration page a BI (5) m1 Select Manual mode ON/ [2] _ Select Automatic mode ON / OFF OFF, ‘Automatic operating made [4] _ Manual operating mode ON/ ON 1 OFF indicator (here OFF indicator (here OFF) ON) Vibration speedsetpoint [6] _ Increasing the setpoint Reducing setpont 86/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Description Operator's stand “Screed does not float” page (option) 2 1 Fig. 2-48: “Screed does not float” page [1] Switch “Screed doesnot [2] _ "Screed does not float” page float" on. ON / OFF (here: OFF) “Screed does not float” is only switched on as long as the button is being pressed. © Joseph Vigele AG 2013 BAL_1011_2325145_00_en 87/268ote @ re Crown adjustment display page (option) Fig. 2-49: Crowm adustment display page [1] Open crown calbbration [2] _ Indication of actual crown value Ifthe numerical value appears in red in the display field [2], calibration is active. mie Crown calibration display page (option) Fig. 2-50: Crown calibraton display page [1] Set calibration value "TO 0" [2] Reducing the calibrated value [3] Indication of calibrated value [4] _ Raising the calibrated value 88/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013a ce Description Operator's stand Conveyors page Fig. 2-51: Conveyors page [1] Reducing setpoint [2] Rate setpoint [3] Increasing the setpoint © Joseph Végele AG 2013 BAL_1011_2325145_00_en 99/289Description & VOGELE| Operator's stand Distribution augers page Fig. 2-52: Distribution augers page [1] Quick adjustment [2] Reduce material feed [3] Switching material sensor on [4] Material sensor ON / OFF oro Inateation [5] Rate setpoint [8] Increase raterial feed Pressing the quick adjustment button [1] saves the current filing level as a setpoint. 90/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013a ce Description Operator's stand ‘Screed heating display page (option) Fig. 2-53: Screed heating display page [1] Switch screed heating ON/ [2] Screed heating ON / OFF OFF indicator (here OFF) [3] Nominal screed plate: [4] Actual suieed plate temperature (option) temperature (option) Material deflector display page (option) Fig. 2-54: Material deflector display page [1] Raise / lower material deflectors. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 91/289Description & VOGELE| Operators stand Machine data page + 0°C | | feoiv{ f 2 1 Fig. 2-55: Machine data page [1] Open service pages [2] _ Distance counter reset to zero [3] Paving distance counter ——[4]_ Paving speed indication indication [5] Mix temperature indication (option) 92/269 BAL_1011_2325145_00_en (© Joseph Végele AG 2013a ce Description Operator's stand Button assignment service page SW VER 819.1.0.4| DATE 06.09.2012 LZS 45410205} AB UBat +25.48 VI LR +26.48 V} Fig. 2-56: Button assignment service page [1] Check all lights, LED, back- lighting ‘When opening the button assignment service page, the buttons are active. Do not test the buttons during work! mle © Joseph Végele AG 2013 BAL_1011_2325145_00_en 93/289ote @ re ‘Automated grade and slope control socket service page (option) Have the cause of the circuit breaker [3] tripping identified and remedied by an authorised electrician. > Switch circuit breaker [3] on again. Insulation monitoring unit If the insulation resistance drops below a pre-set value, the warning light [1] on the heating tox (5) illuminates. Itis possible to continue working on this day. Nevertheless, prior to further use the insulation fault must be rectified by an authorised electrician. Fig. 2-85: Generator [1] V-belts [2] Generator [3] Bett pulley ‘The 230 V power supply is provided by the generator (6). The ‘generator (6) is driven directly via the belt pulley [3] on the diesel engine. The generator (6) sa brush-less synchronous generator. The generator provides the three-shase power necessary for the screed heating. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 117/288Description VOGELE| s. e 2.08 Advance drive Fig. 2-86: Advance drive (1) Crawler tracks (2) Hydrostatic advance drive (4) Mechanical / hydraulic (option) material deflector ‘The road paver has a hydrostatic advance drive (2). Every crawler track (1 has got its own hydrostatic advance drive (2) which consists of a crawler track gearbox and an adjustable motor. (On both crawler track gearboxes there is a hydraulically releasable ‘spring-actuated multiple disc brake that locks the gearbox when the diesel engine is switched off to prevent unintentional rolling away / movement of the road paver. The brake locks the gearbox immediately after the engine is shut down. After actuating the man drive switch, the spring-loaded multiple dise brake is automatically released by the hydraulic system and allows driving on. The spring-actuated multiple disc brake is coupled to the main drive switch (position P) ‘The material deflector (4) pushes away the mix that is on the ground in front of the crawler tracks (1). This prevents both soiling of the crawler tracks (1) and undesired climbing by the machine. Prior to driving on roads ensure that: + The hydraulic material deflector (4) (option) is raised. + The mechanic material deflector (4) is raised and secured ‘The hopper walls must be locked during all works at the material deflector (4), 118/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013om Steering system 2.09 Steering system Fig. 2-87: Steering system (2) Direction indicator ‘The direction indicator (2) helps the operator to keep to the paving line, ‘The direction indicator (2) must be removed during transport. © Joseph Végele AG 2013 ‘BAL_1011_2325145_00_en 119/289(1) Push roller (2) Material hopper (see page 121) (3) Conveyors (seepage 122) (4) _ Distribution augers (see page 124) ‘The road paver moves and pushes the truck forward with the push rollers (1). During this process the push rollers (1) are in contact with the tyres on the truck. ‘The mix is dumped from the truck into the material hopper (2). The conveyors (3) move the mix to the distribution augers (4), which distribute the mix everly in front of the screed. ‘The push roller (1) can be offset 80 mm to the front. 120/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el 2.40.02 Material hopper le 5 Fig. 2-89: Material hepper [1] Entry fap [2] Material strike-off plates [3] Hopper wall [4] Adjustable material strike-off plates [5] Hopper wall locking ‘The material hopper (2) is used for storing the mix. Entry flap [1] and material strike-off plates [2], 4] prevent the mix falling onto the base. ‘The hopper walls [3] can be raised and lowered separately or together using hydraulics. Entry flap versions ‘= Removable (e.g. for maintenance work) ‘* Hydraulically adustable (only SUPER 1300-3, option) Prevents material from dropping out when the material hopper (2) is closed. During transport or manoeuvring on the construction site, the hopper walls [3] must be raised and locked. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 121/289— oa eS Fig. 2-90: Left conveyor drive unit [1] Conveyor Base plate IB] Right conveyor drive unit Both conveyors (3) have their own drives. ‘The base of the conveyors (3) is made of wear-resistant material so that it can withstand the abrasive properties of the mix. 122/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Description Conveyor unit Fig. 2-91: Conveyor control [1] Sensor [2] Paddle Both conveyors (3) are furnished with a separate control system. ‘A movable paddle [2] is fitted to the sensor [1]. The sensor [1] monitors the charging level of the mix in front of the screed and controls that the ‘conveyor runs at the setpoint speed. The setpoint for the fill level is set via the display on the operator's console. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 123/289Description Conveyor unit 2.10.04 Distribution augers ale 4 3 5 2 1 6 Fig. 2-92: Distribution augers [1] Distribution auger [2] Hydraulic motor [3] Distribution auger hydraulic [4] Distribution auger height adjustment (option, ‘mechanical height SUPER 1300-34) adjustment (option, SUPER 1100-30) [8] End stop 18] Gearbox Both distribution augers (4) have their own drives. Hydraulic motors drive the auger shaft via a chain drive. ‘The drive chain runs in the gearbox [6]. ‘The drive chains are tensioned using adjusting screws on the gearboxes. ‘The distribution augers (4) can be extended on both sides as a function of the working width. ‘The paddle control for the auger works in a si control for the conveyor (see page 122) ‘The auger paddle control cannot be used for paving at basic width. In this case only the ultrasonic distribution auger sensor can be used. F manner to the paddle ‘When the distribution auger is in its lowest position, pay attention that ‘only a minimum ground clearance is available. The distribution augers can be adjusted in height across the entire working width. 124/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Description Conveyor unit 2.10.05 Ultrasonic distribution auger sensor (option) Hs] Fig. 2-93: Ultrasonic distribution auger sensor [1] Too much material LED [2] _ Balanced material level LED [3] Too little material LED [4] Reduce material feed [5] Quick adjustment [6] Filing level nominal value [7] _ increase material feed The ultrasonic sensor monitors the level of the mix and regulates the ‘speed of the distribution auger as a function of the level. If LED [2] comes on, the amount of material is at the set value. * If button ‘increase material feed’ [7] is pressed, the material feed is increased. * Ifbutton ‘Reduce material feed’ [4] is pressed, the material feed is reduced. If only LED [1]is lit, too much material is being fed. To maintain this material level, press button ‘Increase material feed’ [7] until the LED [2] is fit, I only LED [3] s lit, too little material is being fed. To maintain this material level, press button ‘Reduce material feed’ [4] until the LED [2] is fit, The ultrasonic sensor is fitted to the end plate carrier of the screed. Pressing the quick adjustment button [5] saves the current filing level as a setpoint. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 125/289ee em Levelling unit 2.11 Levelling unit 2.11.01 NIVELTRONIC Plus® levelling unit (option) Tig. 2-94: NIVELTRONIC Plus® levelling unit (1) Outer control stand (2) Bracket for sensors (3) Sensors (see page 127) —(4)_Height adjusting spindle. The levelling unit automates level paving and is operated via the outer ‘control stand. 126 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el 2.11.01.01 Sensors Description Levelling unit Mechanical long range sensor Fig. 2-98: Mechanical long range sensor [1] Loop sensor [2] Height sensor [3] Mounting pipe [4] Ski sensor (0.35 m) ‘Screw loop or ski sensor [1], [4] to the shaft of the height sensor [2]. ‘The loop sensor [1] can be used to scan along a reference line (e.g. wire line, kerb) © Joseph Végele AG 2013 BAL_1011_2325145_00_en 1271289ee em Levelling unit Ultrasonic long range sensor Fig. 2-96: Utrasonic long range sensor ‘The ultrasonic long range sensor scans from any reference line in a contact-free manner (@ 0 wite line, kerb stone edge) Tilt sensor VOGELE Fig. 2-97: Tilt sensor [1] Tiltsensor The tilt sensor measures the inclination between the screed arms connected with the traverse beam. 128 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Description Levelling unit Ultrasonic sensor Fig. 2-98: Utrasonic sensor [1] Reference bail [2] Single sensor [3] Snap adapter [4] Mounting pipe The ultrasonic sensor scans the ground without direct contact. The reference bail is necessary for temperature compensation. ‘Thanks to the snap adapter the sensor can be mounted and removed ‘quickly (e.g. when terminating the works). © Joseph Végele AG 2013 BAL_1011_2325145_00_en 129/289rs ea eS 2.11.01.02 Spirit level Fig. 2-99: Spit level [1] Spirit level ‘The spirit level [1] indicates the tilt on the sored in relation to the horizontal. Ihe position of the screed can be read using the level glass ‘on the spirit level [1] and adjusted on the outer control stands. 130/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Description Cleaner unit 2.13 Cleaner unit 2.13.01 Cleaner unit with release agent tank Tig. 2-100: Cleaner unit [1] Release agent tank ira) IB] Rocker switch (41 15] Pump 161 [7] Hand nozzle 18] ‘A cleaner unit is available as an option. Filler Operation light Hose drum Filter The cleaner unit is used for applying the release agent by means of a hand nozzle. ‘The pump [5] conveys the release agent from the release agent tank to the hand nozzle via a hose. ‘The hose drum [6] is used for winding and unwinding the cleaner unit hose easily. ‘The hose has a standard connection for fitting the hand nozzle [7] and is ‘connected to the cleaner unit pump. * Petrol ‘Highly inflammable substances Aggressive substances Do not use the following cleaning agents: Observe the applicable safety instructions for the related cleaning agent. 2.13.02 Shoulder nozzle ‘Asan option a shoulder nozzle with a 2 m hose is available. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 131/289cso ome eS 2.14 Screed connections WW . 3 £5) 1 Se 5 Fig, 2-101: Screed connections 133) nee hemes (5) Screed lock (see page (11) Electrical and hydraulic = cmap (see page 135) 132/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Description ‘Screed connections 2.14.01 Tow point ram Fig. 2-102: Tow point ram [1] Dipstick [2] Scale [3] Tow point ram ‘The screed position setpoint is adjusted using the tow point rams (2). ‘The position of the tow point rams (2) is changed using the screed function on the operator's console and the outer control stands. ‘The scale [2] on the tow point ram (2) provides a rough indication. ‘The scale [2] can be folded out. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 133/289cso ome eS 2.14.02 Screed assist (option) Fig. 2-103: Screed assist [1] Screed assist pressure [2] Screed assist pressure setting vioplay In case of a mix with low bearing capacity, itis possible to reduce the pressure applied to the mix by the screed. ‘The pressure is set at the screed assist pressure adjustment [1] and can be read on the pressure gauge [2]. The screed assist (4) s only active with screed float me 134/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013ee Ge Description Screed connections Fig. 2-104: Screed lock Tt] Locking pin [2] Screed arm quide plate The screed guide plates on the rear wall must be in the outer position in ‘order to support the sored in the correct position. ‘When transporting or manoeuvring on the construction site, both tow point arms (1) on the screed must be in contact with the locking pins [1]. ‘The screed has maximum ground clearance when the screed lifting rams (3) are raised completely such that the attachment point on the tow point arms is in the lowest position. ‘The screed lock is mechat 2.14.04 Electrical and hydraulic tractor / screed connection The electrical and hydraulic attachments for the screed depend on the ‘screed version, Electrical connectors Information on the electrical connectors is given in the Socket section (see page 114) © Joseph Végele AG 2013 BAL_1011_2325145_00_en 135/289Hydraulic connectors Fig. 2-105: Hydraulic attachments [1] Plate Hydraulic hoses ‘The connection identifers are engraved on the plate [1] More information on the hydraulic connections is given in the hydraulic A | conection aagram, 2.19 Screed See screed operating instructions. 136 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el 3 OPERATION . 1 Operation Pay attention to the instructions in the Safety manual for all activities. This section describes how the assemblies and the road paver are ‘operated. Item numbers on ilustrations of specific parts are marked in the text with ‘square brackets J. Fig. 3-1: Overview of operator's console a 14] 117) [20] 4 [54] Main drive switch (10) Conveyors /distribution [15] augers / tamper Control knob for paving [19] speed Operating mode selector [31] switch Raising /lowering, locking [53] screed Starting / shutting down [54] engine Emergency stop Reversing crawler tracks AutoSet ‘Screed heating Adjusting diesel speed ‘Steering joystick © Joseph Végele AG 2013 BAL_1011_2325145_00_en 137/289Operation & VOGELE| Organising the workplace 100 Fig. 3-2: Outer control stand [100] Emergency stop 3.01 General information Before putting the machine into operation and before starting operation, {ollow all instructions cescribed in the section on assembly and conversion (see page 245), depending on the equipment of the machine. Otherwise the machine can be damaged or produce poor results. 3.02 Organising the workplace Before starting the engine, the workplace must be made ready for use. Risk of dazzling due to incorrectly adjusted headlights Incorrectly adjusted spotlights can cause road accidents. + Do not twist spotlights or make similar changes. NOTICE Risk of damage to the machine Cable duct can be jammed or damaged when pivoting, + Ensure that the cable duct is not jammed when pivoting. = The mounting must engage after it has been adjusted. 138 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Operation Organising the workplace Organising the workplace * Unfold the roof (see page 139). + Fitexhaust pipe (see page 140). + Adjust the drivers seat. + Adjust the operator's console. + Adjust the mirrors and the lighting. + Fold out scale at the tow point ram. * Remove the vandalism protection and stow on the left-hand seat console, 3.02.01 Unfolding the roof Fig. 3-3: Unfolding the roof [1] Hole [2] Locking pin [3] Hole 14) Hand pump [5] Pumplever 16] Pump hand lever DANGER Risk of crushing ‘There is a risk of fatal injury when folding the roof. Ensure there are no people on the platform, + Ensure the safety devices are fully fitted. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 139/289Operation Organising the workplace Fold in and secure the roof & VOGELE Remove locking ali from locking pin [2] Pull locking pins [2] out of the bore [3] on both sides. Move pump lever [5] to right to unfold the roof. Insert pump hand lever [6] in the receptacle on the hand pump [4] Unfold the roof by pumping. Insert locking pins [2] into the drill holes [1] on both sides. ‘Secure locking pins [2] using locking clips. ‘The roof has been unfolded and secured. Fit exhaust pipe vvVYvyY sv ai 4 2 5 1 6 Fig. 3-4: Fumes extraction pipe [1] Hook [2] Handle [3] Fumes extraction pipe [4]__Locking clip 1 Pin [6] Exhaust manifold with expansion joint Danger due to hot exhaust pipe The exhaust pipe is very hot - risk of injury! ‘© Observe instruction labels. * Wear personal safety equipment. * If possible, do not touch any part of the exhaust pipe. +_Incase of injuries, seek immediately medical attention. Pull locking clip [4] from the pin. > Hold the exhaust ppe at the handle [2] and push onto the exhaust manifold with expansion joint [6} > Insert locking clip [4] into the pin [5] and secure, 140 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Operation Placing the road paver in operation 3.01 Placing the road paver in operation Check the following points prior to placing the road paver in operation: ‘+ Function of the three emergency stop buttons, ‘+ Function of the safety devices. ‘+ Funetion of the brakes. ‘+ Function of the steering. + Fuel tank and fuel pipes for leaks. + Hydraulic tank and fuel pipes for leaks. * Condition of engine and machine. + Correct seating of the bolted joints. + Engine oil level + Hydraulic oll level * Oillevels in the gearboxes. + Amount of diesel in the fuel tank. ‘+ Amount of liquic grease in the distribution auger gearbox. ‘+ Lubricate the conveyor bearing, + Tension of the crawler tracks, Prior to an extended period of operation or after a long period without ise, the checks mist he made particularly carefully Make sure maintenance has been performed property. All parts relevant for safety must be in proper condition. Top up oils, greases and fuels as necessary. Maintenance schedule and lubricant chart are given in the Chart section (227). Danger due to incorrect operation Risk of injury in case of incorrect operation. + The machine is only allowed to be operated if the operator sits on the driver's seat of the operator's stand. Use an assistant ifthere are areas around the machine which are hard for you to see. Starting the ens Danger due to heavy load The machine may roll away / move unintentionally and can cause fatal injuries. + Prior to starting the machine, ensure there is nobody in the hazard area. Secure the site around the hine, erect barriers. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 141 1289Operation & VOGELE| Placing the road paver in operation ‘Tum ignition key to position 1. Set operating mode selector switch to NEUTRAL and main drive switch to position F. ¥ System boots. ‘Wait unti the start page appears on the display. if necessary, unlock emergency stop buttons [10] and [100] by turning clockwise. Press start engine dutton [54] for 10 seconds maximum. The engine starts. Release start engine button [54]. ‘The engine runs atidle. y v v y START/STOP Svs Leave engine to run at idle for approx. ten minutes. Risk of poisening due to exhaust fumes Exhaust fumes from deesel engines place your health at risk and can ‘cause life-threatening illnesses. + Only run the engine in well-ventilated places. + Inenclosed places lead off the exhaust fumes to the outside. ble Warming up the road paver ‘The warm-up time is approx. 20 minutes, press heating button [31]. Risk of crushing Being drawn in the conveyors / distribution augers causes serious injuries or fatality. Ifyou press button [14], the conveyors, distribution augers and tamper start working. Ensure there are no people or objects in the hazard area. ‘Switching on and off conveyors / distribution augers / tamper ow > Press button Conveyor / distribution auger / tamper [14]. ¥ Conveyors, distribution augers and tamper start up at low speed. ¥ The diode in the button illuminates. > Press button Conveyor / distribution auger / tamper [14] again. ¥ Conveyors, distribution augers and tamper stop. ¥ The diode in the button goes of. 142/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Preparation Cannacting tha cablas Starting the engine Removing the jumper leads Operation Placing the road paver in operation ‘Starting the engine with jumper leads Danger when handling batteries Risk of explosion due to the formation of “detonating gas”, risk of serious injuries. ‘+ Wear personal safety equipment. + Wait a while after opening the trim panel to allow air to enter. + Do not smoke, no naked flames. * Avoid short circuits and sparks. + Do not place tools on the batteries. > Ensure that the batteries have same nominal voltage. > Adischarged battery can already freeze at 0 °C. A frozen battery must be defrosted in a warm room. > Use jumper leads with insulated pole clamps and a cross section of at least 25 mm? > Donot disconnect a discharged battery from the electrical system of the vehicle The pole clamps of one cable must not touch those of the other cable. The loading vehicle and the discharged vehicle must not touch each other. > Connect one pele clamp of ane of the eables to the positive pala af the charged battery (plus sign). > Then connect the other pole clamp ofthis cable to the positive pole of the discharged battery (plus sign). > Connect one pale clamp of the other cable to the negative pole of the charged battery (minus sign) > Connect the other pole clamp of the second cable to the chassis of the discharged vehicle, e.g. to the engine block or to the fastening screw of the engine mounting. Do not connect the pole clamp to the negative terminal of the cischarged battery (risk of explosion) but as far away from the discharged battery as possible. Position the cables so that they will not be seized by rotating parts and can be removed later when the engine is running. v > Start the engine of the charging vehicle and run it at medium engine speed, > Start the engine of the discharged vehicle after about 5 minutes. > Let both engines run for about 3 minutes at medium engine speed ‘with connected jumper leads. ¥ The engine has been started with jumper leads. > Switch on one electrical device on the discharged vehicle (in order to prevent over vottages in the electrical system). Remove jumper leads in reverse order. v © Joseph Végele AG 2013 BAL_1011_2325145_00_en 143/289sate om 3.04 Driving, stopping and turning the road paver pytclaat Danger due to heavy load ‘The machine may roll away / move unintentionally and can cause fatal injuries. ‘+ Prior to starting the machine, ensure there is nobody in the hazard area. + Secure the site around the machine, erect barriers. Observe the admissible values for slopes when operating the machine, see page 228. Risk of falling There is a risk of falling when the machine is moving, Only use the floor to cross the screed with the machine stationary. mle Ifthe main drive switch [1] is actuated, the road paver starts to move after a brief delay. Danger due to eudden etart-up Risk of injury in case of incorrect operation. If the main drive switch is moved out of position (P), the machine moves immediatel Ensure there are no people in the hazard area. me Driving the road paver > Set operating mode selector switch [20] to paving. (Paving) 5 Select diesel speed using diesel speed adjustment [53]. automatic diesel speed adjustment is active, the diode flashes. Pre-select the desired paving speed using control knob for paving speed [17]. Place main drive switch [1] in position F. ‘The road paver pulls away. ¥ v sv Driving the road paver > (manoeuvring, positioning, driving on the road) Set operating mode selector switch [20] to positioning or manoeuvring. Select diesel speed using diesel speed adjustment [53]. Select direction of travel and speed using the main drive switeh [1]. = Position F for driving forward. — Position R for driving backward. The road paver pulls away. vy 7 The road pavers steered using the steering joystick [51]. hale 144 (268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eo co nS Danger due to unintentional rolling away / movement ‘The machine may roll away / move unintentionally and can cause fatal injuries, + Prior to leaving the operator's stand: = Place main drive switch in position P. — Place operating mode selector switch in neutral position. = _ Shut down engine and remove ignition key. Danger due to full braking Risk of injury in case of incorrect operation. Ifthe main drive switch is moved to position (P), the machine stops immediately! ‘Stopping the road paver > Slowly place main drive switch [1] in position P. v_ The road paveris stationary and secured against unintentional rolling away / movement. ‘The road paver can be stopped independently of the operating mode. Turning the road paver on Precondition: the spot — Main drive switch [1] is in position P. = Operating mode selector switch [20] Is set to positioning or manneuvring Keep Reversing crawler tracks button [15] pressed. Move steering joystick [51] to left or right. Regulate speed using the steering joystick [51] The road paver turns to the corresponding direction. Release Reversing crawler tracks button [15]. The road paveris stationary. © KV icany 3.05 Laying pavement Risk of crushing The rising and descending screed can cause fatal injuries. + Prior to raising the screed, ensure there are no people or objects in the hazard area. + There must not be any people under the screed. ‘See booklet on paving. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 145/289om om ore Unlocking and lowering hopper walls Fig. 3-5: Hopper wall locking (Eye [2] Safety chain I] Carabiner DANGER Risk of crushing ‘The moving hopper walls will cause serious injuries or fatality. Ensure there are no people or objects in the hazard area. + Ensure there are no people in the material hopper. + Observe instruction labels. 7 SWaRNING Danger due to hot surfaces Parts of the material hopper are very het - risk of injury! + Observe instruction labels. ‘+ Wear personal safety equipment. + Do not touch any parts of the machine if possible. + Incase of injuries, seek immediately medical attention. > Raise hopper walls. > Open safety chain [2] at the carabiner [3]. © Hook carabiner [3] nto eyes [1]. > Lower hopper walls The hopper walls have been unlocked and lowered. | kerting of the hopper walls is described in chapter "Lifing and locking hopper walls" (see page 156). 148 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Operation ‘Manoeuvring the road paver 3.05.01 3.06 Paving with AutoSet In sub-menu AutoSet, selected components (e.g. screed) are moved to transport position in manoeuvring / positioning mode or, after manoeuvring, are prepared for paving in paving mode. (Open the AutoSet submenu. ‘Mark the component which is to be selected for AutoSet. Lay the Set operating mode selector switch [20] to manoeuvring / positioning. Keep the AutoSet [19] button pressed until all AutoSet functions have been performed Components move to "Transport" end position. Manoeuvre the road paver. Drive the road paver to the positioning place. ‘Set operating mode selector switch [20] to paving. Keep AutoSet button [19] pressed. ‘The components selected in the AutoSet sub-menu are moved to the "Paving" end position. ‘You can start paving again. Vv vv v Unlock screed if necessary. Sereed |, Keep middle or bottom button [34] pressed. 4 The screed moves tothe related direction. SSS > Release mile wr lle bull [94]. DD) the seed einai its posi ) © 148 (268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Operation ‘Manoeuvring the road paver Mechanically locking the screed me Fig. 3-6: Mechanically locking the screed [1] Handle [2] Gate BI Pin [4] Guide plate Precondition: = Crown is setto 0%. — Screed arm guide plates on the rear wall are mounted in outer position. ~ Screed is raised. > Pull pin [3] up using handle [1] to the stop. > Pull out pin [3}. > Press down handle [1]. ‘The handle [1] must be securely engaged in the gate [2]. > Lower screed. v_The tow point arms are securely in contact with the pins. v The screed has been locked mechanically. Always secure screed on both sides of the road paver. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 149/289arte om 3.07 Cleaning and shutting down the road paver Cleaning the road paver Danger due to hot surfaces Parts of te materia appe are very ots fn! * Observe instruction labels. + Wear personal safety equipment + Do ntiouch any prs ofthe machine if posse. + Incas fines, seckimmesitely media tention 7 WARNING Risk of crushing Conveyors, distribution augers and tamper run at moderate speed in the cleaning mode and can cause fatal injuries. ‘+ Observe instruction labels. ‘= Do not touch moving parts. ‘= Do not wear loose clothing or jewellery. + Ensure the safety devices are fully fitted. ‘When working on the open material hopper, park road paver on firm, level ground ‘Ailow material hopper, conveyors and auger compartment to run empty before you clean the machine. To keep the road paver ready for use, it must be cleaned daily. (On completion of the paving work, the following parts of the machine must be cleaned: * Hopper * Conveyors * Conveyor base plate * Distribution augers ‘+ Front wall, frame (screed plate) and tamper on the extending screed (see screed operatng instructions) * Push rollers: Danger due to substances harmful to your health Bitumen and solvents contain substances that are harmful to your health. ‘The substances are present in the environment due to evaporation. + Do not inhale vapours. ‘+ Wear personal safety equipment. + Read and observe instruction in the related data sheets. 150/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Operation Cleaning and shutting down the road paver =e > For bituminous mix, use bitumen solvent. In case of concrete paving, clean the parts of the machine listed above with a weter jet. Open bearings and grease nipples must not directly be subjected to the water jet. > Leave conveyors and distribution augers to run in the cleaning mode and spray thoroughly to prevent material adhesion, > Collect used release agent in a suitable container as necessary. Release agent /bitumen mixture may not be released into the environment. > Dispose of left over release agent correctly to protect the environment. v If this cleaning work is not performed, material will become bonded to the moving parts and as a result the functions degrade. Chain breaks and premature wear on the drive elements will be the ‘consequence. ‘Shutting down the road paver Danger due to full braking Risk of injury in incorrect operation. Ifthe main drive switch is moved to position (P), the machine stops immediately! > Before operating the main drive switch, abvays move the control knob for paving speed to position (0). NOTICE Danger due to emergency stop If the machine Is stopped using the emergency stop button, ‘+ Mechanical parts are subjected to increased wear. * Electrical and hydraulic components may be damaged. (Only operate emergency stop button in case of danger. Do not use emergency stop button to stop the machine normally. v v Place main drive switch [1] in position P. Remove any mix stil in the road paver. Set diese! speed adjustment [53] to MIN. ‘Switch off screed heating [31]. ‘Switch off screed functions and all conveyor and compaction systems. Lock hopper walls and screed. Lower screed. > Place operating mode selector switch in neutral position. vy vv vvy Do not shut down engine immediately after operation at full load. Leave to run at idle to allow time for temperature equalisation. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 151/289Operation & VOGELE| Cleaning and shutting down the road paver ‘Switch off engine. Press starting / shutting down engine button [54] for ‘approx. 2 seconds until the engine stops. ‘Tum the key in the ignition lock to position 0. Remove ignition key. Pivot in operator's console and secure if applicable. Pivot back pivoted out driver's seat, check engagement. Protect operator's console with vandalism protection (see page 152), > Dismantle outer control stands and stow away. > Dismantle sonsors and stow away. The road paver has been shut down. v vvvvy 3.07.01 _ Fitting the vandalism protection Fig. 3-7: Fiting the vandalism protection [1] Operator's console [2] Lock [1 Vandalism protection [4] Locking mechanism Precondition: Locking mechanism [4] is open. Place vandalism protection [3] on the operator's console [1]. Place ‘down the side to which the lock [2] is attached first. } Check for correct seating, > Secure the vandalism protection [3] with the lock [2]. > Check that the locking mechanism [4] clicked into place. The vandalism protection has been fitted. 152/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Operation ‘Transporting and loading the road paver 3.08 Transporting and loading the road paver Fig. 3-8: Lashing and lifting points [1] Bottom lifting points [2] Top lifting points [3] __Lashing points The top lifting points [2] are undemeath the driver's seats. The top lifting Points [2] are accessible after pivoting the driver's seats outwards. Observe the applicable regulations on loading / load securing. Danger due to heavy load The machine can fall down. Risk of fatal injuries! ‘= Incase of crane loading, observe lifting points and operating weight of the machine. * Read safety manual. ‘= Observe instruction labels. * Do not walk or stand in the hazard area. Danger due to excess width or excess height Excess width or excess height can cause property damages and injuries. + Fold roof and secure, ‘+ Remove all attachments. Pivot in driver's seats completely and secure. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 163/289Operation Frets nsoatg eto 6 Preparation: Loading the road paver on a low loader , 1 Driving / lashing the road paver on a low loader > Free machine of ccarse soiling. v Secure all loose parts (e.g. boxes, trim panels). Retract screed extending unit. 7 7 Remove screed ex‘ension (separate screed operating instructions). Remove all attachments. Remove direction indicator. Raise screed and lock. Risk of falling With the screed raised, the first step can be higher than 600 mm. Risk of falling! ‘+ When entering the machine, step carefully and hold on to the hand rails with both hands. Never jump off the machine. vv 7 Place distribution auger in the highest position. Raise hopper walls and lock If necessary, push in awnings and lock them. Raise material deflector and secure. Lock side trim panel. Fold in and lock mirror holder. Pivot in driver's seats completely and secure. vVvvvy Svv ‘The road paver is prepared for loading. The individual actions are described in the related sections. Observe load securing specifications (see page 234)! Precondition: ‘Intact lashing devices with marking and valid inspection mark ‘+ Mats increasing the friction, which are free of dust, oll and grease + Lashing points on the vehicle designed for this load > Use strong loading ramps of sufficient width that are secured in Position, Free loading ramps of soiling (e.g. oil, snow, ice). Furnish loading ramps with slip-free covering (non-slip mat). Observe maximum ramp angle allowed. v Drive road paver up in a straight ine. Unlock screed and lower evenly onto the low loader. vvvy 154/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Operation ‘Transporting and loading the road paver li Loading the road paver using a crane Danger due to hot exhaust pipe The exhaust pipe is very hot - risk of injury! + Observe instruction labels. ‘+ Wear personal safety equipment. * Ifpossible, do not touch any part of the exhaust pipe. + Incase of injuries, seek immediately medical attention. Remove exhaust pipe. ‘Swing away the roof and secure it. Lash road paver and screed to the low loader. The road paver has been driven onto a low loader and lashed vy Tie down screed to the means of transport using suitable lashing ‘equipment at the lashing points [3] provided Observe crane loading specifications (see page 233)! Remove the rocf (with front frame, brace and roof supports). (Only suspend the road paver at the iting points [1] and [2] marked. Do not lift the road paver at the screed! Observe lifting points and operating weight of the road paver. Pivot out driver's seats. vv vvy Load road paver using a crane. Remove lifting gear from the lifting points [1], [2]. Pivot in driver's seats. ‘The road paver has been loaded with a crane. v 156 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Operation ‘Transporting and loading the road paver 3.08.02 Moving the awning (only SUPER 1300-3) Fig. 3-10: Moving the awning [1] Locking clip, » Undo locking clips [1] at front and rear. > Pull out awning, > Lock awning using locking clips [1]. ¥ The awning has been pulled out and locked. ‘The awnings must be retracted in the following situations: Transport * Manoeuvring on the construction site + Folded roof © Joseph Végele AG 2013 BAL_1011_2325145_00_en 187 1289ones = toon tine 3.08.03 Folding in the roof Removing exhaust pipe Fig. 3-11: Fumes extracton pipe [1] Hook [2] Handle [B]_ Fumes extraction pipe [4] Locking clip 15} Pin [6] Exhaust manifold with expansion joint Danger due to hot exhaust pipe ‘The exhaust pipe is very hot - risk of injury! ‘+ Observe instruction labels. ‘* Wear personal safety equipment. * possible, do not touch any part of the exhaust pipe. Incase of injuries, seek immediately medical attention. ¥ Pull exhaust pipe up using handle [2] and place on the hooks [1]. Engage the exhaust pipe in the pins [5] > Insert locking clip [4] into the pin [5] and secure. 158 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Operation ‘Transporting and loading the road paver Fig. 3-12: Folding in the roof [1] Hole [2] Locking pin [3] Hole [4] Hand pump [5] Pump lever [6] Pump hand lever Risk of crushing ‘There is a risk of fatal injury when folding the roof. ‘Ensure there are no people on the platform, Ensure the safety devices are fully fitte Folding in and securing the roof Fold down the criver’s seats. Remove locking clip from locking pin [2]. ull locking pins [2 out of the bore [1] on both sides. Move pump lever [5] to the left to fold the roof in. Insert pump hand lever [6] in the receptacle on the hand pump [4]. Fold the roof in oy pumping. Insert locking pins [2] into the drill holes [3] on both sides. ‘Secure locking pins [2] using locking clips. The roof is folded in and secured. vVyYVvvvY Sv © Joseph Végele AG 2013 BAL_1011_2325145_00_en 169/289a ow e i i ane 3.09 Towing the road paver To tow the road paver + Switch the advance drive to free circulation, + The brake must be released using the hand pump and then reactivated after towing, ‘The road pavers allowed to be towed a maximum of 300 m. The maximum towing speed should not exceed 10 m/min. Maintain a sufficiently great bend radius. Danger due to heavy load ‘The machine may roll away / move unintentionally and can cause fatal injuries. ‘+ Ensure there are no people in the hazard area. ‘+ Wear personal safety equipment. + Secure machine against unintentional rolling away / movement. * Secure the site around the machine, erect barriers, ‘+ Only tow using suitable vehicles, pay attention to weight of machine, + Only tow using towing bar. hale 160/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eo cs vue SEE ‘Switching the advance drive to free circulation Fig. 3-13: Hydraulic pumps [1] Setscrew [2] Lock nut [3] Position of setscrews on hydraulic pumps: > Secure road paver against unintentional rolling away / movement. > ‘Shut down diesel engine. Open left side trim panel. Remove the four protective caps. Loosen the fourlock nuts [2] of the setscrews [1] by half a turn, ‘Screw the setscrews [1] in until they are flush with the lock nuts [2] Lock setscrews [1]. The advance drive has been switched to free circulation. vvvy sv © Joseph Végele AG 2013 BAL_1011_2325145_00_en 161/289Operation Towing the road paver Releasing and activating the brake Releasing the brake Fig. 3-14: Hand pump [4] Ball valve [5] Hand pump Io] Lever > Secure road paver against unintentional rolling away / movement. > Open the rear right side trim panel. ¥ The hand pump is accessible. > Tum ball valve [4]. The ball valve must be transversely to the direction of travel > Release the brake by pumping using the lever [6] The brake is released if the manual force applied does not increase anymore or the pressure relieve valve in the pump block is activated. ¥ The parking brake has been released and the road paver can be moved as required. NOTICE Risk of damage to the machine Driving with released brake irreparably damage the brake. + Re-activate the brake after towing. Drive the machine only with activated brakes 162/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013om J vernal Activating the brake > Loosen the four lock nuts [2] by half a tum. Undo the setscrews [1] and secure using lock nuts [2] Fit protective caps. Tum ball vaive [4]. The ball valve must point in direction of travel. Start the diese! engine. > Place main drive switch [1] in position P. Precondition: There is no fault in the hydraulics. The brake has been reactivated and the road paver secured against unintentional roling away / movement. vvy y 3.10 Backup manual actuation 3 4 ae wv [A 2 5 Fig. 3-15: Valve block [1] Left conveyor [2] Vibration [3] Left distribution auger [4] Right conveyor [5] Right distribution auger PEats= Danger due to heavy load ‘The machine may tip overfroll away and cause serious injuries. + Ensure there are no people in the hazard area. ‘= Backup manual may only be performed by qualified personnel Use the backup manual only for emptying the conveyor units in view of a real danger. Backup manual actuation > Press in the rear side of the respective solenoid coil [1] - [5] using a thin object. v_ The backup manual performed. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 163/289Operation Operating the NIVELTRONIC Plus® components (option) om 3.11 Operating the NIVELTRONIC Plus® components (option) | isms cuter cont stand must be installed in order to operate NIVELTRONIC Plus® 3.11.01 Ultrasonic sensor Fig, 3-16: Ultrasonic sensor with working area (1) LED [2] Working area NOTICE Risk of damage to the machine ‘The reference bail can get stuck and break. + Be careful during operation. Ensure the reference bail does not get stuck The ultrasonic sensorhas a working range of 300 to 600 mm. The recommended working range is 350 to 550 mm. Within this range the status LED is continuously illuminated. If the sensor is outside the working range, the status LED flashes. Working range ‘Status LED < 300 mm flashes quickly (10 Hz) [300 to 350 mm flashes slowly (2 Hz) [350 to 550 mm illuminates: [550 to 600 mm flashes slowly (2 Hz) > 600 mm flashes quickly (10 Hz) Reference bail error flashes quickly (10 Hz) (Chart 3-1: Working range of the ultrasonic sensor 164/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Maintenance ‘Special safety instructions 4 MAINTENANCE | Pe semton te instucons inthe Safety manual or al actives 4.00 Special safety instructions [i] me le Maintenance and repair work that must be organised or performed is. ‘described in this section. The capacities and service interval are given in the maintenance schedule (see page 235). ‘The specification of greases and oils is described in the lubricant chart (see page 239). All safety devices and trim panels must be correctly re-fitted after maintenance and repair work. Regularly check nuts and screws for tightness and re-tighten if, necessary! The tightening torques are given in the tightening torque chart in section (see page 237). To ensure the correct operation of the road paver and to reduce wear and tear, the maintenance and care intervals must be observed. ‘These include, among others, cleaning, greasing, lubricating and oiling ‘components and parts. ‘All maintenance and repair work described in this section is only allowed tobe performed by personnel who have been trained by Végele AG. This ‘works include repars to the hydraulic, electrical and brake systems as ‘well as to the engire. Observe the service check booklet and follow the service intervals ‘according to these operating instructions. So the claims under warranty will remain. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 165/289soos om TT ‘Observe following safety instructions: + Repair, care, maintenance and cleaning work as well as the rectification of malfunctions are solely to be undertaken with the ‘engine stationary! ‘Secure road paver against unintentional placing in operation and rolling away. + Park road paver on firm, level ground ‘+ Shut down engine and remove ignition key. + Observe safety instructions to avoid injuries and accidents. + Attach warning to cperator's console. ‘+ Hydraulic pipes are to be replaced at the latest after six years use (including a storage period of max. two years). + Only use original Vogele fiers and grease, fiers from other manufacturers may cause damage to the engine. ‘Place old fier in a suitable container to collect escaping waste oil or fuel. * Dispose of fitters, waste oil, fuel, release agent and grease correctly and with due care for protecting the environment. 4.01 Chassis / safety devices Perform the following service work: + Ensure the safety devices are not damaged and function correctly! + Check operating instructions and warnings are fitted to the road paver and legible; replace damaged labels. * Check the following components for freedom of movement and oil Piston rod of the gas struts on the bonnet = Brackets for side trim panels + Regularly clean handles of the maintenance flaps on the road paver. + Regularly visually inspect the gas struts on the bonnet for oil leaks. If the force is reducing or oil is escaping, replace gas struts. ‘+ Minor damage, corrosion or paint residue on the gas strut piston rod vill result in the failure of the strut, the seals will be damaged. + Check warning feature; for example on extending the screed to the lef, the warning light on the left outer control stand must flash; ‘on reversing the road paver an acoustic warning must be audible (option), + Check emergency stop button, hom and beacons (option) for correct function daily. ‘+ Check, lighting, reflectors and lens for damages and replace if necessary. 186 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Maintenance Engine / motor group 4.02 Operator's stand me Fig. 4-1: Pivoting besring on the operator's stand [1] Pivoting bearing [2] Diamond plates Perform the following service work: > Keep steps, hand rails, platforms and grids dry and clean. > Ifthe diamond plates [2] on the platform have become thinner than 0.5 mm due to wear, we recommend replacing them. > Check adjusting lever on the operator's console and driver's seat for freedom of movement; lubricate regularly. > Lubricate pivoting bearing [1] on the driver's seat. > Keep operator's console clean, The film on the operator's console may become detached. > Clean operator's console only with a special cleaning agent (see page 235). Ia different cleaning agent is used, the warranty will be void. Check roof for damage prior to start of work or before loading it on a low loader. 4.04 Engine / motor group 4.04.01 Engine compartment To increase the engine's service life, the engine manufacturer recommends that 2 thorough overhaul is carried out by authorised personnel after 5000 operating hours. Furthermore the ergine manufacturer recommends an extended service | after 1000 operating hours by technical personnel and the extended ‘service Il after 3000 operating hours by authorised personnel ‘This maintenance has to be carried out additionally to the maintenance intervals given in the maintenance chart. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 167/289Maintenance Engine / motor group 4.04.01.01 Checking the engine oil level Manually checking the ‘engine oil level Fig. 4-2: Engine compartment [1] Dipstick Check engine oil level prior to every time the machine is used. Only check engine cil level when engine is cold and stationary; if the ‘engine is warm, wait five minutes. ‘Shut down road paver and remove ignition key. Open left side trim panel. ‘The dipstick [1 Pull out dipstick [1] and wipe with a clean, flufF-free cloth Insert dipstick [1] to the stop and pull out again. Read oil level on the marks. The oil level must be between the Min ‘and Max marks, top up if necessary. Re-insert dipstick [1] to the stop. Lock left side trim panel. Engine oil level has been checked manually. accessible. vavy vv sv 168 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eadaltaoe 4.04.01.02 Draining the engine oil Fig. 4-3: Oil drain hose [I] Plug [2] Fastening clip [3] Ollarain nose Fig. 4-4: Engine compartmont [4 Filler cap, The engine oil fiter must always be changed when the engine oil is, LL | changed (see page 171). © Joseph Vigele AG 2013 BAL_1011_2325145_00_en 169/289sores om Te Draining the engine oll The oll must be at operating temperature, otherwise leave road paver to run at idle for ten minutes. An oil drain hose [3] is fitted to the sump. The oil drain hose is Izid on the left of the road paver in the direction of travel and is fastened io the inside of the front wall. Shut down engine and remove ignition key. > Open left side trim panel. Danger due to hot oi's, greases, fuels and machine parts Oils, greases, fuels and machine parts can be very hot - risk of injury! ‘= Observe instruction labels. * Wear personal safety equipment. ‘© Avoid contact. #_ Incase of injuries, seek immediately medical attention. > Loosen fastening cip [3]. The oil drain hose for the engine oil is beside the oil drain hose for the ‘gearbox oil. Do not mix up oil drain hoses. For safety reasons trace back the hoses. Have a suitable container at hand, pay attention to capacities. Open the bonnet. The filler cap [5] is accessible. Open filer cap [5]. Insert oil drain hose [4] through the opening [1] into the vessel Undo plug [2] using a suitable tool Completely drain ol. Clean plug [2] and tighten. Lay oil drain hose [4] without kinks and secure with fastening clip, Dispose of waste oil with due care for protecting the environment. ‘The engine oil has been drained. vVvSvY vy ¥ With the anti-twist protection fitted, remove the clamps (option). > Hold a suitable container undemeath the engine oil fiter [1] to collect Undo engine oil fiter [1] using a strap wrench, unscrew and dispose of with due care for protecting the environment. > Wipe up any oil that escapes using an absorbent cloth and dispose of taking due care for the protection of the environment. > Clean the sealing surface on the fier carrier using a clean, fluff-ree loth. Slightly oil seal on the new engine oil iter. Risk of solling of the fiter. > The filter must never be prefilled. Screw on engine oi fiter [1] by hand until the seal is in contact, > Tighten engine oil filter [1] by % of a turn (approx. 15 - 17 Nm). Tighten the clamps of the ant-twist protection (option). > Fill engine oil (see page 173). > Place road paver for a brief period in operation and check sealing ‘surfaces for leaks. > Check engine oil level (see page 168). Bolt on the engine compartment cover. The engine oil fiter has been changed. 172/268 BAL_1011_2825145_00_en © Joseph Végele AG 2013,el Maintenance Engine / motor group 4.04.01.04 Filling the engine oil Fig. 4-6: Engine compartment [1] Filler cap > Open filler cap [1]. Fill in fresh oil, make use of a funnel, Fill sump with engine oil to the Max mark on the dipstick. Close filler cap [1]. Leave engine to run for a short time. Check engine ol level (see page 168). Lock bonnet. The engine has been filled with cil. v vv cv © Joseph Végele AG 2013 BAL_1011_2325145_00_en 173/289Maintenance Engine / motor group 4.04.01.05 Checking the V-belts Checking the V-belts Fig. 4-7: Checking the V-belts U1] V-belts Danger due to rotating parts! Alternator and fan V-belts are freely accessible. If the machine is runt there is a risk of injury! + Always switch off the engine first and remove the ignition key. + Observe instruction labels. + Do not reach into rotating parts. + Do not wear loose olothing or jewellery. > Regularly visually inspect the entire periphery of the V-belts [1] for ‘wear (cracks, fraying, etc.). > Replace damaged V-belts. > In case of new V-belts, check tension after 15 minutes running, ¥ The V-belts have been checked. 174/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eo wos 4.04.01.06 Checking the belt tension Fig. 4-8: Using belt tension meesuring instrument [1] V-belts [2] Scale for deflection [3] Inateator arm [4] Push-button [5] Guides ‘The pre-tension on the V-belt [1] can be checked using a belt tension measuring instrument. ‘The V-belt has the correct tension when the value given in the maintenance schedule meets that on the belt tension measuring instrument when pressing in the belt. Danger due to rotating parts! Alternator and fan V-belts are freely accessible. If the machine is running, there is a risk of injury! Always switch off the engine first and remove the ignition key. (Observe instruction labels, Do not reach into rotating parts. Do not wear loose clothing or jewellery. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 175/288Maintenance Engine / motor group om Checking the belt tension > Insert the indicator arm [3] into the measuring device. > Place the guide [5] onto the V-belt [1] between two pulleys. The stop must touch on the side. > Press push-button [4] at right angles to the V-belt [1] uniformly, until the spring unlatches audibly or tangibly. > Carefully it the measuring device without changing the position of the indicator arm [3]. > Read the measured value at the intersection (arrow), scale [2] and the indicator arm [3]. » Ifnecessary tension again and repeat the measurement. If the values match each other, the belt tension is correct, otherwise the \V-belts must be tensioned. 4,04.01.07 __Tensioning the engine v-belts Fig. 4.9: Tensioning mechanism for V-belts [1] __ Fastening screw [2] Adjusting screw Danger due to rotating parts Alternator and generator V-belts are freely accessible. If the machine is running, there is a risk of injury! + Always switch off the engine first and remove the ignition key. + Observe instruction labels. + Do not reach into rotating parts. + Do not wear loose clothing or jewellery 178 (268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eo woes > Loosen fastening screw [1]. > Tum adjusting screw [2] until the correct belt tension is achieved. — Turn adjusting screw [2] clockwise: Tension V-belt — Tur adjusting screw [2] counter-clockwise: V-belt tension is, reduced, > Check the belt tension (see page 175). > Ifthe belt tension is correct, tighten fastening serew [1] . The V-belt has been tensioned. 4.04.01.08 Checking the engine mounting Fig. 4-10: Engine mounting [1] Engine mounting Risk of crushing ‘The engine compartment cover is heavy. It may drop down when lifted - risk of crushing. + Wear personal safety equipment. + Donat overestimate your own strength. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 171288Maintenance & VOGELE| Engine / motor group Danger due to rotating parts! Alternator and fan V-belts are freely accessible. If the machine is running, there is a risk of injury! Always switch off the engine first and remove the ignition key. ‘+ Observe instruction labels. = Do not reach into rotating parts. Do not wear loose clothing or jewelle ‘Checking the engine > Unscrew the engine compartment cover and open the right and left mounting side trim panels. Check the engine mountings [1] for tightness and tighten, if req Check the condition of the engine mountings. Bolt on the engine station cover and close the right and left side trim Panels. ‘The engine mounting has been checked. vvv < 4.04.02 Fuel supply DANGER Danger due to system under pressure The fuel eyetem is preseuriced. Risk of fatal injuries! ‘* Shut down engine and remove ignition key. ‘= After shutting down the engine, wait 1 minute until the pressure has dissipated. + Do not work on the fuel pipes. + Never undo hgh pressure pes (recto sytem pes) 7 WARNING Danger due to incorrect handling of fuel Pel and el ames nana and ae hart your heath * Do not smoke, no naked flames. + Do otha vapours +_Wear personal safety equipment (safety gloves). NOTICE Risk of damage to the engine ‘The fuel system is very sensitive and can be damaged by soiling. * When working on the fuel system, pay attention to cleanliness. * Clean area around the related parts, ‘= Cover areas, of which soiling could peel off, with new clean film. Dry damp areas using compressed ai 178 (268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eo woes After all works at the fuel system it has to be bled and a test run as well ‘asa leak test have to be carried out. Itis also necessary to bleed the fuel ‘system after maintenance works at the fuel system or in case of an empty tank. le | When filing the tank with fuel, ensure no dirt enters the tank. | Never run the fuel tank empty. 4,04.02.01 Draining and changing water from fuel pre-filter Fig, 4-11: Fuel pre-fiter [1] Electrical connection [2] Drain valve [3] Fuel pre-fiter Drain water from fuel pre-fiter [3] when a corresponding error message appears on the display on the operator's console. Danger due to incorrect handling of fuel Fuel and fuel fumes are inflammable and are harmful to your health. * Do not smoke, no naked flames. Do not inhale vapours ‘= Wear personal safety equipment (safety gloves) ‘Only work on the fuel supply when the diesel engine is cold and shut down. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 179/289ne Stoo 6 Dre jing the fuel pre-filter > Shut down road paver and remove ignition k > Open left side trim panel The fuel pre-fiter [3] is accessible. Place a suitable container under the fuel pre-fiter [3] Open the drain valve [2] and drain the liquid. Observe the draining process and close the drain valve [2] on transition from water to fuel Dispose of liquid w'th due care for protecting the environment. ‘Start engine and check the system for leaks. The fuel pre-fiter has been drained. vv VAY v cv Changing the fuel pre-filter ¥v ‘Shut down road paver and remove ignition k Open left side trim panel ‘The fuel pre-fiter [3] is accessible. Disconnect the connector for electric monitoring [1] Place a suitable container under the fuel pre-fiter [3]. Open the drain valve [2] and drain the liquid completely. Loosen fuel prefiter cartridge [3] using a strap wrench. Drain the remaining fuel in the container. Dispose of the fuel prefilter in an environmentally safe manner. Clean the sealing surface of the filter carrier and the mating face of the filter head using a clean, fluf-free cloth. ‘Slightly wet the sealing surface of the new fuel prefiter with fuel. ‘Screw on new fuel pre-fiter cartridge manually (17-18 Nm). ‘Screw on drain valve [2] and tighten (1.6 + 0.3 Nm). Fit the connector for electric monitoring [1]. Dispose of old fuel with due care for protecting the environment. > The fuel pre-fiter has been changed, VV VY VY YVYVVYS¥ vv After changing the filter, the fuel system must be bled (see page 183). hale 180/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eo wos 4.04.02.02 Replacing the fuel filter Fig. 4-12: Fuel fter [1] Fuel fiter Danger due to incorrect handling of fuel Fuel and fuel fumes are inflammable and are harmful to your health. ‘+ Do not smoke, no naked flames. * Do not inhale vapours, + Wear personal safety equipment (safety gloves). NOTICE Risk of damage to the engine ‘The fuel system is very sensitive and can be damaged by soiling, + Donot fill new fiter cartridge with fuel. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 181/289Maintenance Engine / motor group 6 Replacing the fuel filter (Only work on the fuel supply when the diesel engine is cold and shut ‘Shut down road paver and remove ignition key. Open left side trim panel. The fuel fiter [1] is accessible. Place suitable container under the fuel filter [1] to collect the escaping fuel. Undo fuel filter cartidge using a strap wrench. Dispose of fuel fiter cartridge with due care for protecting the environment, > Wipe up any fuel that escapes using an absorbent cloth and dispose ‘of taking due care for the protection of the environment. Clean the sealing surface on the fiter carrier using a clean, fluff-ree loth. Slightly oil the seal on the new fue! fer or moisten with diesel Screw on fuel fiter cartridge by hand until the seal is in contact, Tighten fuel filter cartridge by % of a tum (approx. 10 Nm). Check fuel system for leaks. Lock left side trim panel ‘The fuel fiter has been changed. After changing the filter, the fuel system must be bled (see page 122). i vVovevy ¥ vov vy cv 182/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Maintenance Engine / motor group 4.04.02.03 Bleeding the fuel system Fig. 4-13: Bleeding the fuel system [1] Bleed screw [2] Fuel filter ‘Only work on the fuel supply when the diesel engine is cold and shut i ‘Shut down road paver and remove ignition key. (Open the bonnet, Loosen the bleed screw [1]. Press the button ‘Start / stop engine’ briefly. The fuel pump delivers fuel. Observe bleed plug [1]. When fuel starts to emerge, tighten bleed plug [1] (6.5 + 1.3 Nm). Start engine and operate at idle or low load for approx. 5 minutes. Check fuel filter [2] for leaks. Close bonnet. ‘The air has been bled from the fuel system. vvavyyvy v v av © Joseph Végele AG 2013 BAL_1011_2325145_00_en 183/289Maintenance & VOGELE| Engine / motor group 4.04.03 Combustion air / air intake Fig. 4-14: Ar fiter housing [1] Cam lock [2] Housing cover BB] Main fiter [4] Secondary filter [5] Dust collection container i Never operate the engine without air filter, not even for a short ime! When working at the air intake, extreme cleanliness must be observed. Close off the intake opening, if necessary. Dispose of old filter elements ‘according to the regulations. Danger due to rotating parts! Alternator and fan V-belts are freely accessible. If the machine is runr there is a risk of injury! = Always switch off the engine first and remove the ignition key. ‘© Observe instruction labels. * Do not reach into rotating parts. + Do not wear loose slothing or jewellery. 184/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Maintenance Engine / motor group Changing the filter > le =e > Open the bonnet. v The air fitter is accessible. Unlock cam locks [1] and remove the housing cover [2]. Pull out main fier [3] Pull out secondary filter [4]. Empty dust collection container [5] occasionally, at the latest when itis heal ful Carefully wipe cut inside of housing with @ damp cloth. Do not wash out or brush main filter [3]. Never clean filter cartridges with petrol or other liquids. Danger due to airborne particles ‘When blowing out the filter screen, particles can become airborne and cause eye injuries. * Wear protective goggles. + Wear personal safety equipment vy vv v » Blow out main fiter [3] using dry compressed air (max. § bar). Blow out from the inside out. > Carefully check main filer [3] for damage to the fitter paner (use a light behind) and to the rubber seals. = Donot re-use a damaged main filter [3]. — Replace main filter [3] atthe latest once a year, independent of the usage of the machine. ‘As minor damage is very difficult to see, Vogele AG recommends to install always a new main fiter [3]. Replace secondary filter every third time the main filter [3] is maintained or every two years. Pull out secondary filter [4] Do not clean secondary fter [4] and do not re-use after removal. Insert new secondary fiter [4]. Insert main fitter (3) Close housing cover [2] Fit and fasten cam locks [1]. Dispose of old fiters with due care for protecting the environment. Close bonnet. The fters have been changed. vvvy Svvvv © Joseph Végele AG 2013 BAL_1011_2325145_00_en 185/289Maintenance Engine / motor group 4.04.04 Cooling system Checking the cooling system Fig. 4-15: Combined cooler [1] Combined cooler [2] Right side trim panel Never run the engine without coolant. Visually check cooler each time prior to starting work. Danger due to hot coolers ‘The coolers / radiator and parts of the coolers / radiator may be very hot - Fisk of injury! ‘= If possible do not touch any parts of the radiator / coolers. ‘© Observe instruction labels. + Wear personal safety equipment. > Shut down road paver and remove ignition key. > Ensure the combined cooler [1] is hand warm. > Open right side trim panel [2]. > Visually inspect combined cooler [1] for damage (leaks, damaged fins, etc.) > Visually inspect combined cooler [1] for soiling and clean with ‘compressed air. Do not point jet of compressed air directly at the fins. > Close right side trim panel [2]. ¥ The cooling system has been checked. 1868 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013eo wos 4,04.04.01 Checking and topping up coolant Fig. 4-16: Checking end topping up coolant [1] Expansion vessel [2] Filler cap [3] Signt giass Danger due to hot coolant Cooler and coolant can be very hot and be under pressure! Risk of scalding! ‘= Allow the cooling system to cool down. ‘© Observe instruction labels. + Wear personal safety equipment. * Avoid contact with cooler and coolant. Incase of injuries, seek immediately medical attention. [i | Never operate the engine without coolant, not either for a short time! Checking the coolant level >» Open bonnet ard right side trim panel. > Check coolant level in the sight glass [3] when the engine is cold and if necessary fill with coolant to the middle of the sight glass [3], ¥ The coolant level has been checked. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 187/289Maintenance Hydraulic oil feed 6 Filling the coolant 1 Checking the antifreeze 1 4.05 Hydraulic > Open filler cap [2]. Fill in fresh coolant, make use of a funnel Close filler cap [2]. Allow engine to warm up until the thermostat has opened (approx. 95 °C). ‘Shut down engine. Check coolant level in the sight glass [3] when the engine is cold and if necessary fill with coolant to the middle of the sight glass [3]. ¥ The coolant has been filled. The cooling system bleeds itself automatically after filing. vv 7 y 7 > Check the antifreeze using 2 commercial antifreeze measuring instrument, Required coolant mix ratio, see page 231. feed Danger due to hot oi's, greases, fuels and machine parts Oils, greases, fuels and machine parts ean be very hat - risk of injury! ‘© Observe instruction labels. © Wear personal safety equipment. + Avoid contact. + _Incase of injuries, seek immediately medical attention. DANGER Danger due to hydraulic oil escaping under pressure ‘The cil in the hydraulic system is under pressure - risk of fatal injury! + Lower hopper walls. * Set down screed on the ground. ‘= Switch off all conveyor and compaction systems. ‘© Shut down engine and remove ignition key. ‘After shutting down the engine, wait 1 minute until the pressure has dissipated. * Attach warning to cperator's console. + Secure machine against switching on again or recommissioning. «Wear personal safety equipment. NOTICE Risk of damage to the machine ‘The machine may be damaged if bio-oil is mixed with mineral oi * Before bio-oil is added, all parts that have been in contact with mineral coil must be thoroughly cleaned and flushed, 188 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013Maintenance Hydraulic oll feed 4.05.01 4.05.01.01 le Oil supply If the road paver is operated with bio-cil, the partial flow fiter must be fitted. ‘Observe the following instructions: ‘The quality of the hydraulic oil as the lubricant and operating medium of every hydraulic system is crucial to the performance, reliability and service life of the hydraulic elements used in the road paver. ‘= The operating temperature has a significant impact on malfunctions. and damage in the system. * Pay attention to cleanliness during installation work on hydraulic units during maintenance, repair or replacement. * Select oils caretuly + Regularly check the oil level. + Observe oil change intervals. + Always change the oil when itis at operating temperature. + Replace filters es specified + Avoid soiling ofthe oil cooler ‘+ Thoroughly clean road paver and all connections prior to dismantling. + Protect disconnected, open pipes against dirt. ‘= Tighten leaking threaded fittings at operating temperature when de- pressurised. Changing the hydraulic oil 4 Fig. 4-17: Hydraulic tank (I) [1] Oildrain hose [2] Fastening clip B] Plug [4] Filing indicator © Joseph Vogele AG 2013 BAL_1011_2325145_00_en 189/289Maintenance VOGELE| Sere, e Fig. 4-18: Hydraulic tank (I) [5] Filler cap Draining the hydraulic oil The oil must be at operating temperature, otherwise leave road paver to run at idle for ten minutes. An oil drain hose is installed on the hydraulic tank. The oll drain hose is laid on the right-hand side of the road paver in the direction of travel. © Observe special safety instructions at the beginning of this section. > Open the rear right side trim panel. Danger due to hot oi's, greases, fuels and machine parts Oils, greases, fuels and machine parts can be very hot - risk of injury! ‘© Observe instruction labels. ‘+ Wear personal safety equipment. Avoid contact. + Incase of injuries, seek immediately medical attention. 190/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013vee y vvvy Top up hydraulic tank to the middle of the level gauge [4] with hydraulic oil, ‘The gauge is located on the hydraulic tank and can be accessed after opening the right rear side trim panel. The filling level must be visible in the level gauge [4] and should be between ‘% and % of the max. level. With the diesel engine shut down, the level [4] must not be below the MIN mark. Cloee filler cap [5]. ‘Start road paver and bring to operating temperature. ‘Shut down engine. Check the level in the level gauge and top up oil if necessary. ‘The hydraulic of has been filed. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 191/289Maintenance VOGELE| Sere, e 4.05.01.02 Cleaning the filter screen Fig. 419: Filter screen [1] Filler cap [2] _ Sealing flange I] Fiter sereen ‘The fiter screen [3] sits in the hydraulic tank and must be cleaned. > Open the oil supply cover. > Open filler cap [1] (with integrated, one-way filter element) and dispose of correctly. } Loosen fastening screws and remove sealing flange [2] } Remove filter screen [3] with lower and upper seal from the filler. Danger due to airbome particles ‘When blowing out the filter screen, particles can become airborne and cause eye injuries. * Wear protective goggles. ‘Wear personal safety equipment. > Clean filter screen (3] from the outside in (blow out with compressed air) Fit fiter screen [3] in the reverse order of removal. Close hydraulic tank with new filer cap [1] Dispose of waste cil with due care for protecting the environment. Close the oil supply cover. The filter screen hes been cleaned or replaced. vvyv v sv 192/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Maintenance Hydraulic oll feed 4.05.01.03 Changing hydraulic oil fitters, me Fig. 4-20: Hydraulic tank Uy) Filler [2] Runback suction fitter ‘connector [3] Runback suction filter cap [4] Overfiew oil iter connector [5] Overfiow oil ster In case of soiling the pressure in the filters increases. When the capacity of the filters is exhausted, a corresponding error message appears on the ‘operator's console display. Pull off connector [2] or [4] on the related filter and check whether the ‘error message is stil indicated on the display on the operator's console. If this is not the case, the related filter must be replaced. Both filters (runback suction filter and overflow oi fitter) must be replaced land the filter screen cleaned when the hydraulic oil is changed. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 193/289Maintenance Hydraulic oil feed Changing the overflow oil filter Fig. 4-21: Overfiow oil iter [1] Overfiow oil filter > Observe special safety instructions at the beginning of this section. > Open the rear right side trim panel. Danger due to hot oils, greases, fuels and machine parts lls, greases, fuels and machine parts can be very hot - risk of injury! ‘© Observe instruction labels. * Wear personal safety equipment. ‘+ Avoid contact. Incase of injuries, seek immediately medical attention. ¥ The overflow oll fiter [1] is accessible. Undo overfiow oil fiter [1] using prongs. Unscrew the overflow oil filter and place in a suitable vessel. Dispose of the old filter in an environmentally correct way. > Wipe up waste oil with an absorbent cloth and dispose of with due ‘care for protecting the environment. ‘Slightly cil sealing ring on the new overflow oil fiter [1]. Fit overflow oil fiter [1]. Ensure the sealing ring is correctly seated and ensure it is not damaged. Tighten the overflow oll fiter by hand. Tighten the overflow oll fiter manually by a further half tum. Close the rear right side trim panel. ‘The overflow oil fer has been changed. ¥ y v y Svvy 194/268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013ee Ge Maintenance Hydraulic ol feed Changing the runback suction filter Fig. 4-22: Runback suction fiter [1] Runback suction filter [2] Top part BI Cap > Observe special safety instructions at the beginning of this section. Unscrew and remove the oil supply cover. Risk of crushing ‘The operator's stard base plate is heavy. It may fall when lifted - risk of ‘crushing, + Wear personal safety equipment. + Do not overestimate your own strength. 7B WaRNING Danger due to hot oils, greases, fuels and machine parts ils, greases, fuels and machine parts can be very hot - risk of injury! + Observe instruction labels. + Wear personal safety equipment. + Avoid contact. + In case of injuries, seek immediately medical attention. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 195/289srnanes @ Ga MS > Unscrew cap [3]. Caution: The cap [3] is made of plastic and may be damaged. The runback suction fier [1] is accessible. > Remove top part [2]. > Remove runback suction fiter [1] with dirt trap and place in a suitable ‘container. Dispose of the old fitter in an environmentally correct way. > Fit new fiter with clean ditt trap. Check for correct seating of the filter. > Clean thread in the fier housing. > Fill fiter housing with new cil to the top edge of the filter. > Fit top part [2]. Clean seal and oil ightly. > Close cap [3] > Tighten fastening screw. > Screw on the oll supply cover. The runback suction fter has been replaced. 198 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013el Maintenance Hydraulic oll feed 4.05.02 Pump distribution gearbox 4.05.02.01 Changing the gearbox oil Draining the gearbox oil Fig. 4-23: Draining the hydrautie oll [1] Oildrain hose [2] Fastening clip [Plug [4] Sight glass Check the correct gearbox oil level in the pump distribution gearbox using the sight glass [4] each time prior to starting work. The level must be visible in the middle of the sight glass [4]. The oil must be at operating temperature, otherwise leave road paver to. run at idle for ten minutes. An oil drain hose [1] is fitted to the sump. The oil drain hose is laid on the left of the road paver in the direction of travel and is fastened to the inside of the front wall. > Observe special safety instructions at the beginning of this section. > Open left side trim panel. Danger due to hot oils, greases, fuels and machine parts ils, greases, fuels and machine parts can be very hot - risk of injury! ‘+ Observe instruction labels. + Wear personal safety equipment. + Avoid contact. + Incase of injuries, seek immediately medical attention. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 197/289Maintenance Hydraulic oil feed @ Loosen fastening clip [2]. The oil drain hose for the gearbox oil is beside the oil drain hose for the engine oil. Do rot mix up oil drain hoses. For safety reasons trace back the hoses. Have a suitable container at hand, pay attention to capacities. Guide oil drain hose [1] into the container. Undo plug [3] using a suitable tool Completely drain ol. Clean plug [3] and tighten. Lay oil drain hose [1] without kinks and secure with fastening clip [2]. Dispose of waste ail with due care for protecting the environment. The gearbox oil has been drained. 7 vVvvvy cv Adding gearbox oil 5 Fig. 4-24: Filler cap [5] Filler cap > Open the bonnet. Y The filler cap [5] is accessible. 198 / 268 BAL_1011_2325145_00_en (© Joseph Végele AG 2013om 4.05.03 Changing partial flow filter for Maintenance Hydraulic oll feed > Open filer cap [5]. > Fillin fresh oil, make use of a funnel. > Fill sump to the middle of the sight glass [4] with fresh oil. > Close filler cap [5]. > ‘Wipe up any oil that escapes using an absorbent cloth and dispose of taking due care for the protection of the environment. > Allow engine torun for approx. two minutes. > Allow gearbox to warm up. > Shut down engine. > Check oil level at the sight glass [4] and top up with oll to the middle of the sight glass [5] if necessary. > Check engine / pump distribution gearbox unit for leaks. > Close bonnet. > Close left side trim panel. v The gearbox oilhas been filed. Fig. 4-25: Partial flow fiter for bio-oi! [1] Cover [2] Seal [B] Screw [4] Filter element NOTICE Risk of damage to the machine ‘The machine may be damaged if bio-cil is mixed with mineral oll. * Before bio-cil is added, all parts that have been in contact with mineral oll must be thoroughly cleaned and flushed. © Joseph Végele AG 2013 BAL_1011_2325145_00_en 199/289