VOGELE OPERATING INSTRUCTIONS VISION 5100-2 2125422_01_en rier number (© Joseph Végele AG 2016 avlw] VOGELE Publisher Joseph Végele AG Joseph-Vgele-StraBe 1 1-67075 Ludwigshafen Germany Phone: + 49 (0) 6 21 /81 05-0 http://www. voagele. info Document name BAL_1382_2125422 01_en ‘Translation of the original operating instructions First issue date 04.10.2009 o1.01.2016 © Joseph Vogele AG 2016 ‘The reproduction, distribution and utilisation of this document as well as the communication of the contents to others without express authorisation Is prohibited. Offenders will be held liable for the pay- ment of damages. all rights reserved in the event of the grant of @ patent, utility model or design. 2/253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016a VOGELE — —_tattoor contents, CONTENTS 1 General 1.00 Introduction. 1.00.01 Changes / rights reserved 1.00.02 Packaging and storage wns 3.00.03 Markers and symbols used in these instructions 1.00.04 Safety markers 1.00.05 Signal words. 1.01 Documentation. 1.02 Usage. 1.02.01 Correct use... 4.02.02 Incorrect use 4.02.03 Residual hazards srnsssnsenn 1.02.04 Climatic conditions .. 1.03 Protection of the environment 1.04 Disposal 1.05 Declaration of conformity. 1.06 Type plate 1.07 _ Noise and vibration figures 1.07.01 Saund power level 1.07.02 Sound pressure level... 41.07.03 Vibration information for the operator.. 1.08 Technical data.. 1.09 Personnel - qualifications and obligations. 1.09.01 Personal safety equipment. ane aan 1.10 General safety instructions 3.10.01 Safety manual . eve 1:40.02 Information about electrica/eletrenie parts 2.41 Hazard area. 44.01 Safety distance between working area and road trafic. 1.42 Signs. 1.42.01 Labelling diagram. 3.12.02 Labels used.. 2 Description. 2.01 Chassis /safety devices. 2.01.01 Operating instructions and Warnings nese 2.01.02 Trim panels 2.01.03 Lighting / warning features. 2.01.04 Sockets... 2.01.05 Safety devices . 2.01.06 Chassis joseph Vogele AG 2016 BAL_1382 212542201 en 3/253Contents lw] VOGELE 2.02 Operator's stand 4s 2.02.01 Operator's console 2.02.02 Driver's seat with rails 2.02.03 Outer control stand, auxiliary control. 2.02.04 Vandalism protection. = rote se 89 2.02.05 Umbrella... 2.03 Not used 2,04 Engine / motor group 2.04.01 Engine compartment . 2.04.02 Fuel Supply. nnn se 2.04.03 Exhaust system . 2.04.04 air intake.. 2.04.05 Cooling system. ~_ ormarmensariareaniST 2.05 Hydraulic oil feed. 2.05.01 Hydraulic tank casa isi 2.05.02 Pump distribution gearbox 2.05.03 Pumps. 2.05.04 Control blocks. 2.06 Electrical system 2.08.01 24 power supply 2.06.02 Switch box 2.08.03 Heating box. 2106.01 Gonerator 2.08.05 Limp Home. 2.07 Not used 2,08 Advance drive 2.09 Steering system.. 2.10 Conveyor unit. 2.10.01 Material hopper. 2.10.02 Conveyors. 2.40.03 Distribution augers..rssnnnnasensen 2.40.04 Distribution auger ultrasonic sensor... 2.41 NIVELTRONIC Plus® levelling unit (option) 241,01 Sensors. eapeeennene 2.11.02 Spirit evel . 2az 2.43 2.13.01 dnearrensrersecl 2414 2.14.01 Tow point ram 2.14.02 Screed lock.. 2.14.03 Electrical and hycraulc tractor / screed connection 2.44.04 Tow point arm adjustment mss snnsensevm aa Sareea 2.15 Not used 4/253 BAL_1362 2125422 01_en © Joseph Vagele AG 2016a VOGELE ————__srattccrcontents 2.46 132 247 132 248 133 249 134 3 135 3.00 19 the road paver in operation 136 3.01 Driving, stopping and turning the road paver. 138 3.02 Laying pavement, 140 3.02.01 Unlocking and lowering hopper walls. 140 3.02.02 _Lower distribution auger... 141 3.03 Manoeuvring the road paver 142 3.03.01 Raising / lowering the screed and locking vss ae sane 43 3.04 Cleaning and shutting down the road paver 3.05 Transporting / loading the road pave 149 3.05.01 Locking the hopper wale... 153 3.06 Towing the road paver 3.07 Limp Home Activation . 157 3.08 Operating the NIVELTRONIC Plus® components (option! 159 3.08.01 Big Ski. ani sca esa 158) 3.08.02 Ultrasone senso. on sone sssnne 163 4 Maintenance. 4.00 Special safety instructions 4.01 Chassis /safety devices. 4.01.01 Ventilation system.. ce etic 167 4.02 Operator's stand 4.03 Not used. 4.04 Engine / motor group. 4.04.01 Engine compartment. 4.04.01.01 Changing the engine oil fiter.. 168 4.04.01.02 Checking the engine cil level. — sasrean sae AL 4,04.01.03 Changing the engine oil. ere eaetiea rel 7o! 4.04.02 Fuel supply 174 4.04.02.01 Fuel pre-fte 175 4.04.02.02 Replacing the fuel filter 2177 4.04.03 Ar intake. sosnnnnnnnsnnnninnis 1478 4.04.04 Cooling system sonrn BL 4.04.04.01 Changing the coolant. ssa aaa ie IB 4.05 4.05.01 4.05.01 4.05.01, Hydraulic oil feed Hydraulic tank 185 .01 Changing the hydraulic oil 185 .02 Cleaning the filter screen... 187 joseph Vogele AG 2016 BAL_1382 212542201 en 5/253Contents lw] VOGELE 4.05.01.03 Changing hydraulic ol iter... 4.05.01.04 Bleeding the hydraulic ol ite 4.05.02 Pump distribution gearbox ... 4.05.02.01 Changing the gearbox oil. 4.06 Electrical system. 4.08.01 24V power supply 4.06.02 Sultch cabinet / power supply / socket.. 4.08.03 Generator 4.07 Not used 4.08.01.01 Releasing and tensioning the track bands.. 4.08.02 Advance drive. 4.08.02.01 Changing the gearbox oll. 4.09 Steering system.. 4.10.02, Material hopper/ entry flap. 4.10.03 Conveyors. 4,10,03.01 Tensioning the conveyor chain.. 4.10,03.02 Tensioning the drive chain. 4.10.03.03 Changing the gearbox oll. 4.10.03.04 Cleaning the conveyors. 4.10.04 Distribution augers. 4.10,04.01 Tensioning the drive chain. 4.40,04.02 Changing the gearbox oll... 4.10.04.03 Cleaning the distribution augers.. 441 4.12 4.13 4.13.01 Cleaning filter screen, in the release agent tank (option). 4.13.02 Changing the filter cartridge... 4.14 Screed connections. 4.14.01 Tow point ram 4.14.02 Screed lifting ram .. 4.15 Not used 416 Notused ...... 4.17 Not used 4.18 Lubrication unit. 4.48.01 Central lubrication point ..snsnsess 4.18.02 Central lubricating system (option) 4.19 6/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016a 5.00 5.00.01, 5.00.02 5.00.03 5.00.03. 5.00.04 5.00.05 5.00.06 5.00.07 5.00.08 5.00.08 5.00.10 5.00.44 5.01 5.02 5.03 5.04 5.04.01, 5.04.02 5.05 6 6.00 6.00.01, 6.00.02 6.00.03 6.00.04 6.01 6.02 6.03 6.04 VOGELE — —_tattoor contents, Technical data.. 224 Weights 224 Operation. 221 Dimensions... 223 01 Dimension sheet sere cae Adjusting the compaction systems... 225 Engine / motor group. eer Hydraulic oll feed «..... 227 Electrical system sess -228 Advance driv son sins soins 228 Conveyer unit / distribution 229 Levelling Unit sssssstssssest +228 Central lubricating system (option). Maintenance schedule. Tightening torques. Lubricant table. Separate documentation Documentation on the road paver .. Information materi Fuse assignments 229 Assembly and conversion.. Fitting and setting up the NIVELTRONIC Plus® (option) Fitting and adjusting the mechanical sensors. Fitting and setting up the ultrasonic wide range sensor . Fitting and setting up Big Ski . Mounting and connecting the ultrasonic sensor Adjusting the tow point arms. Fitting and adjusting the steering system (direction indicator) Mounting and connecting the balloon light Offsetting the push rollers joseph Vogele AG 2016 BAL_1382_2125422 01 en 7/253Contents [w] VOGELE 8/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE neon 1 GENERAL 1.00 Introduction In this section you, as the operator, will find important instructions on the operation of the machine and the use of these operating instruc tions. ‘This VOGELE machine is @ 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 vali the safety manual. Please note: ‘These operating Instructions are written for the operator end the ‘maintenance engineer on the construction site. conjunction with ‘These operating Instructions are intended to place you in the position to ‘operate the machine safely and to use its features to the full. ‘They also provide instructions on the function of important attachments and systems. ‘Specific terms are used in these operating instructions. To avoid misun- ceretanainge, you should always use th sama terme. Only qualified, instructed and trained personnel are allowed to work on this machine. ‘The operating instructions, the safety manual and the stipulations and regulations applicable in the place of use must be observed (for exam= ple accident prevention regulations). The use of these operating instructions will make it easier for you: + To familiarize yourself with the machine. + To avold malfunctions due to incorrect operation. ‘Observing the operating instructions: + Will help to prevent dangers. ‘Will increase reliability of the machine when in use on the construc tion site. + Will increase the service life of the machine. + Will reduce maintenance costs and downtimes. Always keep this operation manual on hand, for example in the ma- chine’s toolbox or in the holder provided. ‘Should you receive further information on the machine from us, these Instructions are aiso to be observed and attached to the operating in- structions (for example additional technical information). (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 9/253General Introduction lw] VOGELE If you do not understand the operation manual or specific sections, you should ask your supervisor, dealer representative and/or Vogele Ameri- ca before you start the related activity. {It is important to comprehend, understand, and follow the instructions, recommendations, and notes contained within this manual to ensure the safe operation of this machine. Failure to follow such instructions, recommendations, and notes may restrict, disclaim, or limit any war- ranty claim made concerning this machine. Examples of such unintended uses include: + Operating errors. + Incorract maintenance. ‘+ Incorrect greases, oils or fuels. + Use for purposes that are not stated in the operating instructions. ‘The warranty and liability conditions in the general terms and conditions Published by Vogele are not extended by the above instructions. We reserve the right to make changes without prior notice as a result of technical development. Information and illustrations in these operating instructions are not al- lowed to be copied, distributed, or used for the purposes of competi- tion. ‘Translations are undertaken to the best of our knowledge. No liability ‘can be accepted tor transiation errors or any resulting consequences; ‘also not in the casa that the translation was made by us or was com- missioned by us. ‘The German text Is and remains definitive for all lability claims and ‘claims under the warranty, All legal rights related to copyright are expressly reserved. We wish you every success with your VOGELE machine! ‘There are separate operating instructions for the tractor and the screed. A functional road paver (in the context of the Machinery di rective) 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. {IF you 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. 30/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE General Introduction 1.00.01 Changes / rights reserved We make every effort to ensure these operating instructions are correct ‘and 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 ne liability for malfunctions, fallures or any resulting damage, You must also observe any additional information supplied. 1.00.02 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. If the machines are not placed in operation immediately after unpack- Ing, they must be protected against moisture and dirt. 1.00.03 Markers and symbols used in these instructions e » @ ‘The markers and symbols in these instructions are intended to help you to use the instructions and the machine quickly and safely. Information “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 wil ind a description of the result of a sequence of actions. Item number on assembly illustration Item numbers on assembly illustrations are marked in the text with suurid brackets ( Item number on individual part illustration Item numbers on illustrations of specific parts are marked in the text with square brackets [ ]. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 11/253General Introduction lw] VOGELE 1.00.04 Safety markers >PPPPPPERP ‘The safety marker provides @ visible indication of e 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). Warning of a general hazard ‘This warning marker is used before activities during which risks could arise for several reasons. Warning of hazardous electrical voltage This warning marker Is used before activities during which there are risks of an electric shock, possibly with fatal consequences. ‘Warning of suspended load This warning marker is used before activities during which there are risks due to falling objects, possibly with fatal consequences. Warning of rotating parts ‘This warning marker is used before activities during which there are risks due to rotating parts of the machine, possibly with fatal conse- ‘quences. Warning of tripping hazard ‘This warning marker is used before activities during which there are risks due to tripping, possibly with fatal consequences. Warning of crushing hazard ‘This warning marker Is used before activities during which there are risks due to crushing, pessibly with fatal consequences. Warning of hot surface This warning marker Is given before activities during which there are risks due to hot surfaces. Warning of inflammable substances ‘This warning marker Is used before activities during which there are risks due to inflammable substances, possibly with fatal consequences. 32/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016General Documentation iW} Warning of potenti ‘This warning marker is used before activities during which there are risks due to potentially explosive substances, possibly with fatal con- sequences. ly explosive substances Warning of toxic substances ‘This warning marker is used before activities during which there are risks due to toxic or corrosive substances, possibly with fatal conse- quences. Warning of falling hazard ‘This warning marker is used before activities during which there are risks due to falling, possibly with fetal consequences. Warning of laser beams ‘This warning sign is displayed for activities with a risk caused by laser beams. > PDD! 1.00.05 Signal words Pr This sianal word indicates immediate danger causing serious injuries or death. This signal word indicates possible danger which may cause serious Injuries or death. This signal word indicates possible danger which may cause minor to ‘medium injuries or material damage, Eo 1.01 Documentation {A copy ofthe Instructions must be available to the authorised personnel at any time, ‘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 under~ stood these Instructions. ‘These instructions are intended to familiarise you with basic tasks / ac- tivities on the machine. ‘These instructions contain Important instructions on the safe and cor- rect use of the machine. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 13/253General Usage lw] VOGELE 1.02 1.02.01 1.02.02 Usage ‘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 stendards 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 \Végele safety manuals, The related safety manuals are given in section 5.04.01. A copy of this safety menual must be available to the operator of the machine at all times. Correct use ‘The state-of-the-art machine complies with the applicable safety regu- lations at the time It wes placed on the market in the context of Its cor- rect use. ‘Te was not possible to prevent foreseeable misuse or residual hazards by design means without restricting correct functionality, ‘+ 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 de- ‘scribed in these instructions represent unauthorised misuse beyond the bounds of the manufacturer's liability. Incorrect use ‘The manufacturer is not responsible for any Incorrect use of the ma- chine, Furthermore, any Incorrect use terminates all guarantees given by the manufacturer of the machine. Incorrect uses are among others: + Carrying people. 44/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE General Usage + Leaving the operator's stand during operation. ‘+ Placing in operation, operating the machine from outside the opera- tor’s stand, ‘© Operating the machine with the floor folded up. + Spraying with high-pressure cleaners or fire extinguishing equip- ment. ‘+ Removal of safety devices. + Failure to observe maintenance intervals. + Failure to take measurements and perform tests for the early detec- tion of damage. + Failure to replace wear parts, + Fallure to perform maintenance and repair work. ‘Incorrectly performed maintenance and repair work. ‘+ Use of the machine in potentially explosive atmospheres. 1.02.03 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 thece requirements in practice: + The spacial wemings on the machine, ‘= The general safety instructions in these instructions and in the safety manual. ‘+ The special wernings in these instructions. ‘© The instructions in the safety manual. ‘The operating organisation's instructions on operation. Dangers that may result in fatality / Injury cen arise on the machine due to: + Incorrect use. + Incorrect operation. + Transport. + Miosing safety devices. + Faulty or damaged components. + Operation / use by personnel who have not received traning, in- struction. Pollution can arise due to the machine in case of: + Incorract operation. + Oils, greases and fuels (lubricants, etc.). © Joseph Végele AG 2016 BAL_1382_2125422 01 en 15/253General Usage lw] VOGELE + Noise emissions. Damage can be caused to the machine due to: + Incorract operation. ‘+ Failure to observe operating and maintenance requirements. + Unsuitable oils, greases or fuels. Damage can be caused to other property in the erea where the machine is operated due to: ‘+ Incorrect operation. Performance limitations or limitations on the functionality of the ma- chine can arise due to: + Incorrect operation. ‘+ Incorrect maintenance end repair. ‘+ Unsuitable olls, greases or fuels. 1.02.04 Climatic conditions Low ambient temperature {In cold weather the start performance and the operation of the diesel engine depends on the following points: + Fuels used + Engine oll viscosity ‘+ State of the battery Pieces of advice for the operation in cold weather: + Aftar starting leave engine run until an operating temperature of at least 80°C (176°F) is reached. By reaching the right operating tem- perature, It Is avoided that the inlet and exhaust valves get stuck. + Aftar shutting down the engine the cooling and lubrication systems {are not 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, fil in the right lubricant. + 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 46 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE a General Protection of the environment {At special operating conditions different greases, oils and fuels have to be used. Danger due to starting aid liquids Injuries end demage can be caused when using alcohol or other starting ald liquids. © Donot use aerosol starting alds, such as ether. In this case there is a risk of explosions and Injuries. Acceleration and braking performance are influenced by viscous hydrau- lic oll. At low outside temperatures wait a few minutes after starting the diesel engine unti pulling away. Run the machine only at low load dur- Ing the warm-up phase until the oll of the hydraulic system has heated Lup 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. If the machine Is operated at altitudes higher than 1,000m or above an ‘ambient temperature of 30 °C (86 °F), a reduction of the quantity of in jected fuel is required. 1.03 Protection of the environment Packaging, cleaning agents and waste or left-over greases, olls and fuels are to be recycled in accordance with the regulations on the pro- tection of the environment applicable in the place of use, © Joseph Végele AG 2016 BAL_1382_2125422 01 en 47 / 253General Disposal lw] VOGELE 1.04 Disposal ‘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 ravr materials. Oils, greases and fuels lls, greases and fuels are to be disposed of in accordance with the cor= responding 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 materials in accordance with the related national regulations. Electrics / electronics ‘The electrical / electronic components are not subject to the WEEE di- rective 2002/96/EC and the corresponding national laws (in Germany e.g. Elektro). Send the electrical / electronic components directly to a specialist recy- cling organisation. 38/253 BAL_1382_2125422 01 en Joseph Vogele AG 2016General VOGELE Declaration of conformity 1.05 Declaration of conformity ‘The declaration of conformity is part of the documentation provided seperately by Vogele AG and will be handed over to you on the delivery of the machine. ‘The CE marking cn the machine Is part of the type plate. related to the product ~ that is the machine - which require 2 CE marking, It applies to the combinations of road paver with screed fit- ted. C ‘The pictogram indicates conformity with the applicable EU directives EG-Konformititserklérung Im Sin der £0 Maychnerehine imi eat Joseph Vogole AG ‘Teteph. Vogel Ste 1 {67078 Ludwigehaton + Germany ss le unten sulgldnte Maschine,besienene aus Bezokhmung: Sravtenieriger od Basschmung: Einbaubohia a Te 7 awe: * auras Fesident- FeckdentNrs en Arforserungen or folgendon EG-Rictiin eins Exginzungen suomi 2006/42/EG — Weseninenrentine Joes 108 /E6 Euv-Rerre 2000/18/86 Gerduschomaronsientine ‘Carat Arka! 12, Amana 1 Ou Konfumiatsbowerungsveriaven nach Aang Vit ori the 13, Aran 4 a ontxmansboworungevertanren azn Aran V eoitng AW ane Schallesungspege! wx gemessen 8). Schallestungspegel wx garnet i) Argewondcte hares Nownen EN's00.1 " Bowoalcho Svaforbaurasen. — Sichemat Cratt' Geminsame Anorcorangen) Enso ——_Bewoplche SraBerbaurraney.— Sichehat (Tol 8: Boe. Anerarurgan an Svaterferiger) EN13309 _Baumasennan -Elekromagretecne Vortaghenko von Bene tr de Zunes er reann etcten Her erg Jou Vole AG. Joep: Yop Sica Beran Samay) cass CP Bul. syntto nraunanea SSrenuarommaion © Joseph Végele AG 2016 BAL_1382 212542201 en 19/253General ert [w] VOGELE 1.06 Type plate Fig 11: Type plate [1] Side trim panel right [3] Type plate [2] LD. number All the Information Is of documentary value and is not allowed to be changed or rendered illegible. porn tase te phox ecco: a 1, Series / type EARN ee Soe eRe ESS [EE ee Rear Esc aE 8. Operating weight: ae Tab. 1-1: Data on the ype plate 20/253 BAL_1382_2125422 01 en © Joseph Vogele AG 20163 General VOGELE tase ena viravon igure Engine type plate Enter engine manufacturer, engine type and engine number in chart be- low: a 1, Hersteller (Manufacturer) 2. Engine type Se args pera 1.07 Noise and vibration figures Its not allowed to make any changes to the machine that will result In an increase in the nolse 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 eny changes to the machine. 1.07.01 Sound power level ‘The suund power level is given in section 4. 1.07.02 Sound pressure level ‘The daily noise exposure level (LEX,Sh) of 80dB(A) may be exceed- ‘ed when working in the immediate vicinity of the machine and at the ‘operator's stand. + Wear your personal safety equipment (ear defenders) if necessary. 1.07.03 Vibration information for the operator Whole body vibration Ifthe machine is used correctly, the weighted effective values for the acceleration of whole body vibration at the operator's position and the ‘outer control stands of aw = 0.5 m/s? - in the context of EN 1032: 2003 - are not exceeded. Hand-arm vibration If used correcty, the weighted effective values for the acceleration of hand-arm vibration of ahw = 2.5 m/s? - In the context of EN 1032; 2003 - are not exceeded. 1.08 Technical data The technical data on the machine are given In section 4, (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 24/253General Personnel - qualifeations and obligations lw] VOGELE 1.09 Personnel - qualifications and obligations ‘Only authorised personnel are allovied to perform any activities on the machine. ‘The authorised personnel must: + Be at least 18 years of age. + Be trained in first ald and be able to provide first aid. ‘+ Have read and understood tne sarety manual. ‘+ Ge familiar with and able to apply accident prevention regulations ‘and safety instructions for the machine, ‘+ Be appropriately trained and instructed on how to react in case of a malfunction ‘+ Have the physical and mental faculties to be able to perform his/her responsibilities, tasks and activities on the machin ‘+ Be appropriately trained and instructed for his/her responsibilities, tasks and activities en 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 machine in operation, read: ‘+The operating instructions, + The safety manual. Its 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 machin Follow the instructions below: ‘+ Familiarise yourself with the equipment fitted to the machine. ‘+ Only drive the machine when you have fully familirised yourself with the controls and method of operation. ‘+ Familiarise yourself with your working area. ‘+ Only use the machine for the purpose intended. ‘+ Use suitable iting gear for transport and fitting heavy extensions or accessories, ‘+ Wear your safety equipment, for example safety shoes and ear de~ fenders. 22/253 BAL 1382 2125422 01. en © Joseph Vogele AG 2016VOGELE General Personnel - qualifications and obligations + If defects are found on the safety devices, inform your supervisor without delay. ‘+ Iother 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. + If you detect any conversions and changes to the machine that are carried out without the consent of the manufacturer and impair safe operation, inform your supervisor immediately. + Ensure the machine is always in roadworthy condition. + Ensure the dates for regular safety Inspections by authorised per- sonnel are observed, ‘+ Pay attention to the following items fastened to the machine: ~ Safety markings. ~ Marlangs fer the protection of the health. ~ Safety instructions. ‘+ Read the additional safety regulations end instructions prepered by the operating organisation / employer for special situations. ‘+ Check the completeness and legibility of the ~ Safety markings. ~ Marans fer the protection of the health. ~ Safety instructions (signs, labels, pictograms). + Prior to starting work, obtain information on ~ First aid. = The emergency services (paramedics, fire brigade, helicopter). lable with the contents as required by + Ensure a first aid box is a the regulations. Assistant Assistants are always required if the driver does not have adequate vis- Ibllity of the road or path. It Is 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 expectad 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, you should always familiarise yourself with the signals/hand signals of the assistant. [Note the instructions below: © Joseph Végele AG 2016 BAL_1382_2125422 01 en 23/253General General safety instructions [w] VOGELE Familarise yourself with the dimensions of the road paver and the low-loader. ‘+ If there is visuel contact, wear warning 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 driver and assistant. Service personnel ‘The service personnel are responsible for ensuring that: 1+ The safety markers and Instructions on the machine are in legible condition, “+ The machine Is protected against unauthorised use. ‘+ Repairs are approved by the manufacturer. + The machine Is only operated when It Is fully functional and in cor- rect working order. 1.09.01 Personal safety equipment All parts of the personal safety equipment must be worn during all ac- tivities on and In the area of the machine described in these instruc tions: + Safety shoes + Safety gloves = Ear defenders ‘+ Warning clothing + Protective goggles 1.10 General safety instructions 1.10.01 Safety manual 1.10.02 Information about elect Read the safety manual provided separately by Végele. It is a constitu ‘ent part of the operating instructions. al/electronic parts Plasse adhere te 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 Vagele supplier who will provide a replacement imme- diately, 24/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016General VOGELE overt ety natu Installation Prior to installation, operation and using the equipment, read the op- ‘erating Instructions thoroughly and completely. If you have any ques- tons, please contact your Vagele 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 con- nectors 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 in- structions. If you do not adhere to the instructions listed above, Vagele cannot provide any warranty for the electrical / electronic equipment (ac- cessories). Safety precautions The safety precautions recommended here comply in principle with the directives on the installation and commissioning of electrical sys~ tems, They can be applied to all applications in conjunction with VOGELE equipment. Wiring and The wiring and eabling must be laid correctly In accordance with the cabling 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 ith the applica regulations. Immunity to interference This equipment has been designed and tested for industrial use. Nev- > artheless, the microprocessor technology places @ number of re- {quirements 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. + Donot 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 compo- nents, + Only connect screened leads to earth at one end (equipment end), ‘+ Donot supply any other equipment with the supply voltage from the connection terminals. + Donot 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 al- lowed to be exceeded. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 25/253General Hazard area lw] VOGELE Configuration The equipment has a feclity for configuration by the user. On re~ 1.11 e configuration, the user must only re-configure the equipment to sult the situation in the system, In case of questions on operation and installation, please contact your Vagele supplier {If the precautionary mesoures listed above arc net ebzerved, the ‘equipment or system may fall. Damage caused by the failure to observe the precautionary measures listed above Is excluded from the manufac- turer's warranty. Hazard area Fig. 12: Hazord area [4] 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 ‘leaning work if: = The machine ie stationary and secure, ‘+ The work is performed by authorised personnel. 26 / 253 BAL_1382_2125422 01 en Joseph Vogele AG 2016General () VOGELE ne 1.11.01 Safety distance between working area and road traffic Safety distance plus space for barriers Fig. 13: Safety distance between working area and road tate [1] Road traffic [2] Working area ‘The safety distance between the working area and road traffic to be ‘maintained as per national regulations. 1.12 Signs 1.12.01 Labelling diagram You will find the labelling diagram in the spare parts catalogue. 1.12.02 Labels used Operating instructions and safety manual storage compartment Raed operating Instructions and safety manual before operating or maintaining the machine, (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 27/253sors lw] VOGELE Instruction label: Wear ear protection When operating the machine, the operator must always wear ear pro- tection, Patents Prol ibited action label: no liquids ‘Operator's console and heating box must be protected against rain and ‘must not get in contact with liquids during the cleaning of the ma- chine. Concise instructions Check list Start engine (concise instructions). Special hazards and precautions if welding is necessary. Welding work on the machine is only allowed to be performed by qualified personnel. ‘Three-phase power 24 V sockets 24V DC 28 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016iw] VOGELE “a Flood light chy Beacon O 24V DC 230V AC. Flood light 230 ac HOV AC 10Vs0ckets max. 15A Fill with hydraulic off Fuel type of the drive motor Diesel "GID aro ‘Spraying release agent #5 Auger height scale ‘Specified tension of the drive chain in the auger box To tension / reduce the tension, adjust the tensioning bracket such that the drive chain can move. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 29/253sors lw] VOGELE Excessively loose or taut drive chains will result in increased wear on the idler sprocket and drive bearings. Warning of a crushing hazard / keep clear Warning of a crushing hazard (hand) Lifting points on the machine Its only allowed to use the eyes marked in this way for loading the machine (for example using 2 crane Never lift the road paver at the screed. Lashing points on the machine It is only allowed to use eyes marked in this way for lashing the ma- chine (e.g. for transport on a low-loader). Loading Note for the towing point Instruction on towing 30/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016iw] VOGELE “a Distribution auger risk of trapping Falling Danger due to rotating parts Before opening covers or trim panels wait until all machine compo- nents have come to a complete standstil. Releasing the rubber of the track bands S{4) ‘Tansioning the track bands Az _ Prohibited action label: Access for unauthorised persons is for- Iden Danger due to rotating parts Before getting in contact, wait until all machine components have ‘come to a complete standstill. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 31/253sors lw] VOGELE AS) ‘Warning of a crushing hazard (open belts or chains) Ar® ~ Special greases Use only lubricants of the specified type in the lubrication unit. Drain fuel Draining the hydraulic oi Draining the gearbox oil Draining the engine oil Engine coolant 32/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE Giants oars Ueto 2 DESCRIPTION ‘The road paver assemblies are described in this section. Item numbers on assembly illustrations are marked in the text with round brackets (). Item numbers on illustrations of specific parts are marked in the text with square brackets []- 2.01 Chassis /safety devices ig. 2-1: Examples safety devices of the road paver (1) Operating instructions and (5) Steps warnings (2.01.03) (2) Trim panels (2.03.02) (6) Hand rail (3) Lighting / warning features (7) Chassis (2.01.06) (2.01.03) (4) Safety devices (2.01.05) (8) Towing point Safety deviece are fitted to the road paver to protect people and prop- erty. >> Ensure the safety devices are not damaged and function correct! joseph Vogele AG 2016 BAL_1382 212542201 en 33/253Description Chassis /safety devices [w] VOGELE 2.01.01 Operating instructions and wart gs All labels (operating instructions and warnings) must be fitted to the road paver and be legible. The warnings must be observed. {An overview of the labelling is given in the spare parts catalogue, sec- ton 01.01.00 sqq. ‘The labels (operating Instructions and warnings) are described in the section 1.12.02. 2.01.02 Trim panel Fig 22: Trim panels (2) [1] Bonnet [3] Side trim panel [2] Engine maintenance flap [4] Switch box cover ‘The covers protect against heat, noise and moving parts, The covers must only be opened for maintenance. 34/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE Description Chassis /safety devices Fig. 23: Trim panels (ID) [5] Engine /fuel fiter mainte- [7] Hydraulic tank / sockets rrance flap maintenance flap [6] Heating box cover [8] Operating instructions / safety manual storage com- partment, not shown ‘The bonnet [1] provides protection against heat and noise. It is held up by gas struts. ‘The side trim panel [3] can be locked in two positions. If the driver's seat is pivoted out, the side trim panel can only be locked in the loner position. ‘Trim panels, bonnets and maintenance flap engine [5] are secured with square drive locks when closed. ‘The hydraulic tank / sockets maintenance flap [7] is locked using @ Quide and secured with square key locks. ‘Shut down engine prior to opening trim panels. Below the left driver's seat Is the storage compartment for the operat- ing instructions / safety manual [8]. sseph Vogele AG 2016 BAL_1382 212542201 en 35/253Description A Chassis safety devices wi} VOGELE Extendable shelves / bracket Fig. 2-4: Extendable shelves / brackets [9] Extendable shelf / bracket ‘The extending shelves / brackets [9] must bs inserted during trensport. 36 / 253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016iw] VOGELE Chasse fatty devices 2.01.03 Lighting / warning features Fig. 2-5: Ughting and warning features (1) Tig. 2-6: __Ughtng and warning Features (1) [1] Halogen / Xenon headlights [3] Lateral halogen headlights (option) [2] Horn joseph Vogele AG 2036 BAL_1382_2125422 01 en 37/253Description Chass sey devs [w] VOGELE ‘The warning light on the outer control stand flashes as soon as the screed's left or right extending unit is extended or retracted. ‘of dazzling due to incorrectly adjusted headlig! Incorrectly adjusted spotlights can cause road accidents. ‘+ Do not twist spotights or make similar changes. Warning signal (option) Fig. 27: Warning signal [4] Warning signal ‘An audible warning signal [4], which sounds when the read paver re- verses, Is available as an option. 38/253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE Giants oars Ueto Beacon and balloon light (option) Fig. 2-8: Baacen and balloon light [5] Beacon [6] Balloon tight tne beacen [5] (aption) is Mtted to the hand railing. They are connected using a socket in the heating box on the right rear side of the machine, Up to two balloon lights [6], producing an intense soft light with Halo- gen lamps, are available as an option. The light balloons are fitted at the rear of the driver's seat. joseph Vogele AG 2016 BAL_1382 212542201 en 39/253Description Chassis /safety devices [w] VOGELE 2.01.04 Sockets 5 2 3 4 Fig. 2-9: Sockets (2) [1] Position for connection for [4] Cabling of right outer control ‘external automated grade stand ‘and slope control (option) [2] Retracting and extending [5] Cabling of left outer control screed [3] Connector transmitting measured value / power ‘supply of the seraed stand 40/253, BAL_1382_2125422_01_en © Joseph Vogele AG 2016Description lw] VOGELE chassis safety deviees ig. 2510: Socket (I) [6] Left screed heating connec- [8] Oven connection tion [7] Right screed heating connec- [9] Tilt sensor connection Bion 10 Fig. 2-11; Socket on operator's stand [10] 24 V socket joseph Vogele AG 2016 BAL_1382 212542201 en 41/253,Description Chassis /safety devices [w] VOGELE ea ‘The 24 V socket [10] Is live when the ignition is switched on. 16 15 14 1" 13 ooo Hg. 21d: SOckOCE On Feating box [11] 24 V headlight socket [14] CEE sockets 230 v, 2 KW [42] 24 V beacon socket [15] Switch CEE sockets on or off [13] NEMA socket 410 V, 1.5 kW [16] NEMA socket for switching fon and aff ‘The 24 V sockets for the beacon [42] and headlights [11] are switched on and off vie the operator's console. “The NEMA sockat [13] has @ frequency of 55 to 65 Hz. If used with full throttle, the NEMA socket [13] switches off auto- ‘matically in heating mode to protect the connected devices. Frequency-independent lighting equipments with a maximum of 2 kW (balloon light) each can be connected to the CEE sockets [14]. 42/253, BAL_1382_2125422 01 en © Joseph Vegele AG 2016VOGELE scry doves Chassis /safety devices A DANGER ‘Danger due to electric shock In case of overload, leads and electrical components may be live and cause injury. + The screed heating must not be switched on if an electrical de- vice is connected to the NEMA socket. Ensure that the diesel speed adjustment is set to minimum lev- (ile speed). + Wear personal protective equipment. + Adhere to the safety manual. 2.01.05 Safety devices Fig. 2-13: Safety devices on the road paver (1) [1] Driver's seat locking pin Joseph Vogele AG 2016 BAL_1382_2125422 01 en 43/253,mn ay ns [w] VOGELE Fig. 2-14: Safety devices on the road paver (ID) [2] Screed locking pins [3] Locking pins for hopper walls During transport, the felded hopper walls [3], the raised screed [2] and Huw teliavtea!lviver's seats [1] must be lacked. 44/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016my Description lw] VOGELE Chassis safety devices 2.01.06 Chassis Ventilation system 2 Fig. 2-15: Al niake duct ofthe ventilation system [2] silencer [2] Connecting hose 4 3 Fig. 2-16: Air slots ofthe ventilation system [3] Air slots [4] Conveyor compartment Joseph Vogele AG 2016 BAL_1382 212542201 en 45 / 253,Description Pate [w] VOGELE ‘The ventilation system draws bitumen fumes from the auger compart- ment. ‘The ventilation system comprises a hydraulically driven fan, a connect Ing hose [2] and an exhaust pipe. Fumes from the auger compartment ‘exit through the front exhaust pipe on the silencer [1]. 2.02 Operator's stand Fig. 2-17: Operator's stand ofthe road paver (2) Operator's console (2.02.01) (3) Outer control stand, auxiliary control (2.02.03), not shown (2). Driver's seat with rails (4) Vandalism protection (2.02.02) (2.02.04) ‘The operator's stand Is the command centre and the operator's work plece. all road paver and screed functions are controlled from the oper~ ator's stand. Below the left driver's saat Is the storage compartment for the operat ing instructions / safety manual. 46 / 253, BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE operators and 2.02.01 Operator's console Operator's console with mounting q 2 3 4 Fig. 2-18: Operators console with mounting [2] Guide ratt [5] Foot lever for tlt adjustment [2] Ignition key [6] Locking lever for clockwise rotation [3] Locking lever for sliding [7] Cable duct [4] Locking lever for counter- clockwise rotation If the locking lever [3] is pressed forward, the operator's console can be slid along the guide rail [1]. For pivoting to the left pull locking lever [4]. For pivoting to the right pull locking lever [6]. ‘The cable duct [7] must not be jammed. ‘The mounting must engage after it has been adjusted. A Tonition key (21 ¢ The ignition key switches the road paver’s power supply on and off. + Position 0 - isolates the road paver electrically. The engine is switched off. IF the Ignition key Is set to 0 while the engine Is run- hing, the engine continues running. + Position 1 - activates the control voltage for engine, control elec- trics and lighting, joseph Vogele AG 2016 BAL_1382_2125422 01 en 47 / 253Doras ae lw] VOGELE Overview of operator's console Fig. 2-19: Overview of operator's console [8] Material conveying and pro- [11] Display unit Pulsion (left) [¥] Screed functions (iniddie) [12] Instruction label - Wear ear [10] Material hopper end defenders steering (right) General button functions Arrow buttons (=) =>) ‘The action ofthis contra is retaining / momentary. When the buttons ara released, ‘+ The related unit remains in its actual position or +The actual steering engle is retained. Buttons for switching on and off ‘The action of this contro’ is momentary. If the button is released, ‘+ The related unit remains in its actual position or ©The related unit stops, Buttons with LEDs ‘The light emitting diodes in the buttons illuminate if ‘+ The function is switched on or ‘+The automatic mode is activated. 48 / 253 BAL_1382_2125422_01_en Joseph Vogele AG 2016(] VOGELE Description Operator's stand Operator's console for material conveying and propulsion (left) Fig. 2-20: m1 21 [3] [4] [5] [6] 71 Emergency stop Reversing conveyors Distribution auger height adjustmant Conveyors / distribution au- gers Reversing track bands ‘Control knob for paving speed ‘Operating mode selector ‘switch ‘Operator's console for material conveying and propulsion (Tet) [s]__ Main drive switch [9] Right conveyor [40] Left conveyor [411] Right distribution auger [12] Lafe distribution auger [13] Automatic filling © Joseph Végele AG 2016 BAL_1382_2125422 01 en 49/253Doras ae lw] VOGELE Emergency stop [1] ‘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 but- tons on the machine (operator's console and outer control stands). To reset the emergency stop, turn emergency stop button clockwise. ‘To re-start the road paver, all the road paver's functions must be switched off (operating made selactor cwiteh tn nesiteal and main drive switch to P). Reversing conveyors [2] Both conveyors reverse at moderate speed. Distribution auger height adjustment [3] R ay 1 swe ‘The button has the following functions: ‘+ Top button: The distribution auger is raised ‘+ Bottom button: The distribution auger Is lowered, Se a Conveyors / distribution augers [4] Conveyors and distribution augers are switched ON or OFF. Conveyors and distribution augers run at moderate velocity or speed with this function. ‘This button Is used to warm up the road paver and to clean these units, 1) soem ‘The action of this contro! is retaining / momentary. When it Is re- 50/253 BAL_1382_2125422 01 en Joseph Vogele AG 2016VOGELE —> &y a Description Operator's stand Control knob for paving speed [6] Operating mode selector switch [7] ‘The road paver operating mode Is selected + Neutral = Manceuvring = Positioning + Paving You select the operating modes using the buttons. ‘Once an operating mode has been selected, the related light emitting diode illuminates. If the driver leaves the operator's stand, ‘+ the engine must be shut down and the ignition key removed or ‘+ the neutral operating mode selected: ‘The functions are enabled and adapted to sult the related operating mode. + 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 ~ Menoauvring on the construction site. ~All automatic functions are inactive. + Positioning ~ Sensitive driving, e.g. for moving the road paver to a new start- Ing position. = Road paver reacts exactly to movements of the steering joystick [28]. All automatic functions are inactive. = Paving = Lays the mix on the pre-base, ~All functions and screed float are active. = Reversing is not possible. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 51/253Description Operator's stand lw] VOGELE Main drive switch [8] ‘The road pavers direction of travel is selected: ‘+ Switch position (F) - drive forward ‘+ Switch position (R) - drive backward 4 ‘= Switch position (P) ~ stop (Park position) 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 for- ward, according to the speed range set using the control knob for paving speed. The speed range must have been set with the con- trol knob [6] for paving speed. — Manoeuvring and positioning operating mode: Road paver moves, forward without steps ifthe main drive switch is pressed forward. ‘+ Switch position (R) - drive backward ~ To move backward, release lock (A) by pulling up and move main conve switch backward. = Manoeuvring and positioning operating mode: Road paver moves backward without steps if the main drive switch is pressed back- ward. ‘+ Switch position (P) - stop ~The parking brake is activated. ~ The automated grade and slope control is switched off. = Conveyor and compaction systems in automatic mode are switched off in paving mode. —® Right conveyor [9] ‘The button has the following functions: + Top button: Automatic mode is switched on or off. + Bottom button: = Right conveyor Is switched on or off in manual mode. ~The actual speed is overridden in the automatic mode. e “The bution forthe left conveyor [10] funcBoneikewice: 52/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE operators and a GD 2c + Right button: - Right distribution auger is switched on or off in manual mede. ~The actual speed is overridden in the automatic mode, @ ‘The button for the left distribution auger [12] functions likewise. 2 Automatic filling [13] oe Conveyors and distribution a ‘supply sensors, ifthe supply systems are set to automatic. Operator's console for screed functions (middle) Fig. 221: Operator's console for screed Functions (middle) [44] Left tow point ram [18] Right extending unit [45] Right tow point ram [19] Left extending unit [16] Function not used [20] Screed heating [17] Raising / lowering, locking screed joseph Vogele AG 2016 BAL_1382 212542201 en 53/253Description Operator's stand [w] VOGELE t Left tow point ram [14] ‘The button has the following functions: ‘+ Top button: Left screed tow point ram is raised. ‘+ Bottom button: Left screed tow point ram is lowered. e ‘The button for the right tow point ram [15] functions likewise, 1__ Raising / lowering, locking screed [17] ZS" the button has the following functions: + Top button: Retractor extend the screed lock (option). + Middle button: The reed is raised. Bottom button: The sereed is lowered. Right extending unit [18] ‘The button has the following functions: Right button: The right screed extending unit Is extended. Lat button: The right screed extending unit is retracted e ‘The button for the left extending unit [19] functions likewise. 283 Screed heating [20] ‘Screed heating Is switched on or off. ‘+ Diode flashes: Diagnostics are being performed. ‘+ Diode illuminated: Seraed heating has been switched on. 54/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE Description Operator's stand Operator's console for material hopper and steering (right) o°%o ig. 2-22: Operator's console for material hopper and steering (right) [21] Beacon [27] Hopper walls / entry flap [22] Steering trimming [28] Steering joystick [23] Lighting [291 Hom [24] Function not used [30] Adjusting diesel speed [25] Moving the left hopper wing [31] Switch on / off the engine. [26] Moving the right hopper wing Beacon [21] ‘The 24 V socket for the beacon is switched ON or OFF. Steering trimming [22] ‘The button has the following functions: ‘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 te driven around with the aid of the steering trimming. ‘The steering trimming Is used as a fine steering regulator end keaps 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. joseph Vogele AG 2016 BAL_1382 212542201 en 55/253Description Pont aa [w] VOGELE D Lighting (231 Lighting and the 24 V sockets to which parts of the lighting are con- nected are switched ON or OFF. k Move left hopper wing [25] — ‘The button has the following functions: + Top button: Rees the eft hopper wing. + Bottom button: Lowers the left hopper wing. @e “The button forthe right hopper wing [26] functions similarly. Geigy) Hopper walls / entry tap, lift/lower (271 ‘The button has the following functions: ‘+ Top button: = Raleas hoth hopper alls = Ralses the hydraulic entry flap (option). ‘+ Bottom button: ~ Lowers both hoprer walls. ~ Lowers the hydraulic entry flap (option). Steering joystick [28] ‘The road paver is steered using the steering Joystick. box O ‘An acoustic warning sigral is sounded when pressed. 56/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016(] VOGELE operas @ AK Adjust diesel speed [30] © £0 MAX = masimum production rate ~ Use: Paving and heating * ECO - reduced fuel consumption and wear (reduced production ras) ~ in Padang + MIN de operation Use: Heting and connecting of tools to the 110 Vsockat ‘You can select the diesel speed using these buttons. Once 2 diesel speed has been selected, the related light emitting diode illuminates. If ‘automatic diesel speed adjustment is active, the diode flashes. svsiS'OF | Switch on / off the engine [31] OQ ‘+ Starting the engine: Never keep button pressed for more than 10 seconds. Ifthe button is pressed for more then 30 seconds you must wet at least 2 minutes before re-starting the road paver. ‘* Shut down the engine: Keep button pressed for more than one second. Display unit ig. 2-23: Displey unit [32] Display [34] Navigation block [33] Soft keys [35] Malfunction indicator © Joseph Végele AG 2016 BAL_1382 212542201 en 57/253Description Operator's stand lw] VOGELE isplay [32] ‘The road paver and screed functions are shown en display pages. = = | y i (| Soft keys [33] ‘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 Navigation block [34] Using the navigation block you can change values, activate or deacti- vate functions and navigate on the display pages. ‘The navigation block has the following functions: + ESC button: ~ Back to the previous page = Discard values “+ Return button: > Save values + Arrow butto = Leaf through the display pages ~ Increasing or reducing values Malfunction indicator [35] Flashes if there is 2 malfunction on the road paver. 58/253 BAL_1382_2125422_01_en Joseph Vogele AG 2016() VOGELE Description Operator's stand Start pages Fig. 224: Startpage (D ‘Sub-menu Indication [4] Motfunctions [71 Material sensor position, left conveyor [21 Distribution augers [8] Paving speed [3] Conveyors [9] Steering trimming [4] Screed [10] Material sensor position, right conveyer [5] Vibration Other [6] Information on the road [41] Page number paver ‘The steering trimming indication [9] indicates the steering angle. The steering trimming is only active in the paving operating mode. ‘The soft keys [1]-(6] open the related sub-menu, © Joseph Végele AG 2016 BAL_1382_2125422 01 en 59/253Description Operator's stand [w] VOGELE Fig. 225: Start page (I) ‘Sub-menu [12] Service related section [14] Automatic diesel speed ad- justment [13] Screed heating temperature [15] Brightness / contrast regulation ‘The sub-menu items [12]-[15] open the related sub-menu. 60/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016() VOGELE Malfunctions sub-menu Description Operator's stand ig. 2-26: Malfunctions sub-menu Alternator or D+ malfunc- tion Low engine oll pressure Overflow oll filter clogged Grease low (central lubricat- Ing system, option) Symbol [1] Water trap full 61 [2] Fuel low v7 [3] High coolant temperature [8] [4] Runback suction filter [1 dogged [5] Emergency stop triggered [10] Limp Home If there is a malfunction in the road paver, ‘= the malfunction indicator [35] on the display unit flashes. ‘the related symbol for the malfunction appears on the display. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 61/253Doras ae lw] VOGELE Distribution augers sub-menu [| [Ab 1—_|R[O i 7 2 7 Fig. 227: Disrbuton augers sub-menu [1] Switch reversing en or off [2] Reversing indicator ON/OFF ‘Symbols / indications on the eft relate to the left distribution auger. ‘The behaviour on the right is similar, 62/253 BAL, 13622125422 01_en Joseph Vagele AG 2036(w] VOGELE operas Conveyors sub-menu le Fig. 2-28: Conveyors sub-menu [1] Entry of rate [2] Indication of rate setpoint (in percent of the max, ma- terial low regulation) ‘Symbols / indications on the left relate to the left conveyor. The behav- four on the right is similar. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 63/253Description Operator's stand [w] VOGELE Screed sub-menu 6 5 Fig. 2-29: Screed sub-menu [1] Switch screed freeze on or [4] Screed float lock ON/OFF off Indication [2] Screed freeze ON / OFF indi- [5] Raise distribution auger with cation raise screed ON / OFF indica ton [3]. Lock sereed float [6] Switch raise distribution au- {ger function on or off with False screed ‘Screed float lock [3] Is only active ifthe soft key is pressed. 64/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016() VOGELE Vibration sub-menu Description Operator's stand wy > 0% et ‘ —— © YE tin Al | | 7g. 2-30: Vibration sub-menu [1] Switching on or off "Manual" [5] operating mode [2] "Manual" operating mode ON [6] 1 OFF indication [3] Switching on or off Automat- [7] Ic operating mode [4] "Automatic" operating mode ‘ON / OFF indication Vibration speed entry ‘Actual vibration speed indi- cation (option) Vibration speed setpoint in- ication © Joseph Végele AG 2016 BAL_1382_2125422 01 en 65/253Penne [w] VOGELE ‘Sub-menu with information on the road paver Fig. 2-31: Sub-mend wih information on the rood paver [1] Engine coolant temperature [5] Fuel contents [2] Engine oll pressure [6] Paving distance counter [3] Engine speed (7) Distance counter reset to [4] Operating hours counter 20 ‘The pieces of information on the road paver are read in rows. pending on the slip between the tracks or wheels and the surface, tthe paving distance counter [6] may vary significantly from the ac- tual distance covered. ea ‘The paving distence counter [6] gives an approximate figure. De- 66 / 253 BAL_1382_2125422 01 en joseph Vogele AG 2016() VOGELE Description Operator's stand Screed heating temperature regulation sub-menu Fig. 232 [1] Screed pulsing on/OFF [2] Screed pulsing ON / OFF indication [3] Screed heating temperature regulation ON /OFF [4] Screed heating ON / OFF Indication ‘Screed heating temperature regulation sub-menu Entry of screed heeting tem- perature Screed plate temperature Indleation Indication of screed heating ‘temperatura setpoint © Joseph Végele AG 2016 BAL_1382_2125422 01 en 67/253Description Operator's stand lw] VOGELE Automatic diesel speed adjustment sub-menu Al Fig. 2-33: Automatic diesel speed adjustment sub-menu [1] Automatic diesel speed ad- [2] Automatic diesel speed ad- Justment ON / OFF Justment ON / OFF indication ‘The automatic diesel speed adjustment is coupled to the main drive switch [3]. If the automatic diesel speed adjustment is switched on, the road paver runs at the pre-set diesel speed (MIN, ECO, MAX) efter the main drive ‘switch [8] Is deflected. {IF the automatic diesel speed adjustment Is switched off, the road paver runs at the pre-set diesel speed (MIN, ECO, MAX), independently of the main drive switeh. 68 / 253 BAL_1382_2125422 01 en Joseph Vogele AG 2016(] VOGELE parse ar Brightness / contrast sub-menu (display) >a d o =! a | x +~ “AY OT) OY @ | ig. 2-34: Sub-rienu brightness / contrast (display) [1] Switching on or off contrast [3] Switch on or off brightness adjustment displey ‘adjustment display [2] Contrast value indication [4] _ Brightness value indication (© Joseph Végele AG 2016 BAL_1382 212542201 en 69/253Description Operator's stand [w] VOGELE 2.02.02 Driver's seat with rails Fig. 235: Drivers seat [1] Folding the backrest [4] Adjusting the height [2] Agqusung tne body weight [5] Sliding the driver's ceat to [3] Locking pin Weotieet rear The control elements depend on the design of the seat. ‘When the locking pin [3] Is pulled out, the driver's seat carrier is un- latched. The driver's seat (2) can be pivoted outward. Side trim panels can be damaged ‘The driver's seat support can bump into the side trim panel end damage it. ‘The side trim panels must + Be closed and locked or ‘+ Folded in lowest position and secured. a ‘The locking pin [3] must click in place after the seat was adjusted. 70/253 BAL_1382_2125422 01 en © Joseph Vegele AG 2016VOGELE 2.02.03 Outer control stand, auxiliary control Description Operator's stand Fig. 2-36: Outer control stand 4 (21 [31 [4] [5] Machine connection Tow point sensor connection Distribution auger - sensor ‘connection Auniliary control connection Mounting [61 7 [8] [91 ‘Warning light Emergency stop Button unit Display unit ‘The left and right-hand side functions of the two outer control stands (3) are separated. Joseph Vogele AG 2016 BAL_1382_2125422 01 en 74/253Doras ae lw] VOGELE ‘The outer contro! stands (3) are stored in the compartments on the screed. ‘As an option a levelling unit NIVELTRONIC Plus® is available; this unit is Integrated into the outer control stands (3). Mounting [5] Is fitted to the boxes on the screed. Warning light [6] ‘The left warning light flashes as soon as the screed's left extending unit Is being extended or retracted. The same applias to the right warning light. Emergency stop [7] ‘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 but- tons on the machine (operator's console and outer control stands). To reset the emergency stop, turn emergency stop button clockwise. ‘To re-start the road paver, all the road paver's functions must be switched off (operating mode selector switch to neutral and main drive switeh to P). 72/253 BAL_1382_2125422 01 en Joseph Vogele AG 2016VOGELE Button unit [8] Description Operator's stand Fig. 2-37" Button unit i (21 [31 [4] [5] Distribution auger [6] Slope a Tow point ram [8] ‘Screed extending unit [9] Horn Berm Locking Conveyor ‘The outer control stand mounted on the right Is described in the follow- ing. @ ‘The outer control stand mounted on the left functions likewise. 4yyA——istribution auger [1] The button has the fllowing functions: ‘@ «Top button: Automatic mode fs switched on or off. ‘= Left button: Distribution auger reverses at moderate speed. RR) a= Distribution auger runs at maximum speed. ~The actual speed is overridden in the automatic mode. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 73/253Description Operator's stand lw] VOGELE Slope [2] ‘The button has the following functions: ‘+ Top button: the outer edge of the screed extending unit is raised. ‘+ Bottom button: the outer edge of the screed extending unit is low ered. Right tow point ram [3] ‘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 low- ered. ‘+ NIVELTRONIC Plus® active ~ Top button: The setpoint for the right-hand side tow point sen- sor is increased. ~ Bottom button: The setpoint for the right-hand side tow point sensor Is reduced. Screed extending unit [4] ‘The button has the following functions: ‘+ Right button: The screed extending unit is moved to the right. ‘+ Left button: The screed extending unit is moved to the left Horn [5] ‘An acoustle warning sigral Is sounded when pressed. Screed float [6] ‘Screed float is switched ON or OFF. ‘The screed float is always active in the paving operating mode if the main drive switch [8] Is in position F. Derm [7] ‘The button has the following functions: ‘+ Top button: The berm portion of the screed plate on the screed ‘extending unit is angled upwards, ‘+ Bottom button: The berm portion of the screed plate on the screed ‘extending unit is angled downward. ED! ©: OF Bs Gi GB: 74/253 BAL_1382_2125422_01_en Joseph Vogele AG 2016Description Operator's stand Locking [81 (a) ‘Slope [2] and Berm [7] are flattened and inactive, > conver (G) Pre vun:neonne cent cco inne a, wemutcrcia © Joseph Végele AG 2016 BAL_1382_2125422 01 en 75/253operators [w] VOGELE Operator's stand Display unit [9] 13 . 4 12 ~ wo 15 16 10 — Fig. 2-38: Display unit on the outer control stand [40] Soft keys [14] LED cross for the right side [11] NIVELTRONIC Plus® on the [15] NIVELTRONIC Plus® on the left side ON / OFF right side ON / OFF [12] LED cross for theleft side [16] Display switch over [13] Display Soft keys [10] ARIE) The soft key functions match the symbols shown on the display. NIVELTRONIC Plus® on the left side ON / OFF [11] NIVELTRONIC Plus® on the left-hand side Is switched on and off. With NIVELTRONIC Plus® switched on, the green light emitting diode illuminates, “The button for the NIVELTRONIC Plus® on the right side [15] func~ tions likewise. % _g® LED cross for the left side [12] @ Indicates whether there is a deviation from the standard on the left NIVELTRONIC Plus®. “The LED cross for the NIVELTRONIC Plus® on the right side [14] functions likewise. 76 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016Description VOGELE operas 228 Display [13] +0. 0041 + ‘The road paver, streed and NIVELTRONIC Plus® (option) functions are 0.003 +0. 0h omni H. Percentages on the display pages alvways relate to the maximum valk ue. YE Display switch over [16] TRE cance vetween NIVELTRONIC Plus® start page and a deplay page. If NIVELTRONIC Plus® (option) is not active, the display switch over [16] changes between the brightness / contrast display page and a display page. Display pages ‘The display has the following pag + NIVELTRONIC Plus® = Machine (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 77/253Description Operator's stand [w] VOGELE NIVELTRONIC Plus” start page Fig.239: _ NIVELTRONIG PUS® start page NIVELTRONIC Plus® left-hand ‘Tow point sensor selection Quick adjustment [3] Tow point sensor type (hera: mechanical wide ange sensor for string line mode) [4] Actual tow point sensor val- ue [5] Tow point sensor setpoint [6] Automated grade and slope control sensitivity [7] Screed float NIVELTRONIC Plus® right- hand side [8] Screed float [9] Automated grade end slope control sensitivity [10] Tow point sensor setpoint [11] Actual tow point sensor value [12] Tow point sensor type (here: ultrasonic wide range sensor for ground made) General [13] Open NIVELTRONIC Plus® parameter display ‘The NIVELTRONIC Plus® start page is displayed ifthe ignition is switched on and the NIVELTRONIC Plus® (option) activated. “The tilt sensor can be selected for the left or right side of the road paver. Using the quick adjustment [2] the setpoints for the sensors are adjust ‘ed to the actual value, which now becomes the new setpoint. 78 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE operators and ‘Symbols for the tow point sensors 24 V switch box eerie een) Et (left- and right- Perec} ‘Mechanical height ce elm” fu Ultrasonic wide range sensor for ‘ground / string line mode Mechanical wide range sansor for ground / string line mode Tab. 2-1: Symbols for the tow point sensors NIVELTRONIC Plus® parameters Fia.2-40: _ NIVELTRONIC Plus® Parameter [1] Open NIVELTRONIC Plus® [3] Open NIVELTRONIC Plus® ‘sensor calibration sensitivity [2] Return to NIVELTRONIC [4] _Open brightness / contrast Plus® start page ‘adjustment (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 79/253Description Operator's stand lw] VOGELE Fig.2-41: _NIVELTRONIC Plus® sensor callration NIVELTRONIC Plus® left-hand side [1] Inereasing actual sensor val- [5] Actual sensor value [2] Reducing actual sensor value [6] Sensor type (here: ultrasonic wide range sensor for ground mode [3] Actual sensor value General [4] Sensor type (here: mechani- [7] Return to NIVELTRONIC cal wide range sensor for Plus® start page tring line mode) ‘The increasing / reducing actual sensor value symbols [1]-[2] set the ‘actual value to the variable measured. 80/253 BAL_1382_2125422 01 en Joseph Vogele AG 2016VOGELE NIVELTRONIC Plus® sensitivity Description Operator's stand Fig 2-2: NIVELTRONIC Pas®weratvigy NIVELTRONIC Plus® left-hand NIVELTRONIC Plus® right- side hand side [1] _ Increasing sensitivity [4] _ Sensitivity indication [21 Reducing sensitivity General [3] _ Sensitivity indication [5] Return to NIVELTRONIC Plus® start page Ifthe value for the sensitivity indications [3], [4] Is low, the response time of the units slows down. Brightness / contrast adjustment (display) Fig.2-43: _Brighiness / contrast adjustment (display) [1] Increasing brightness [6] [2] Reducing brightness 71 [3] Actual brightness sensor [8] value [4] Brightness value indication [9] [5] Contrast value indication ‘Actual temperature sensor value Increasing contrast Reducing contrast Return to NIVELTRONIC Plus® stert page (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 81/253Penne [w] VOGELE Machine pages (layout) Using the soft keys Fi end FS you can change to the next or previous pege. Percentages on the pages always relate to the maximum valu Layout of machine pages Fig. 2-44: Layout of machine page (example: vibration) [1] Open previous page [5] Open next page [2] Operating mode indication [6] _ Increase setpoint Automatic / Manual / OFF [9] Automated grade and slope [7] Selecting automatic / manu- control sensitivity al / OFF operating mode [4] Page symbol (here vibration) [8] Reduce setpoint Disable screed float page Fig.2-45: Disable screed Moat page [1] Disable screed ficat indica- [2] Disable screed float ton ON / OFF ‘The button [2] Is momentary. If the button [2] Is pressed, screed float Is disabled. 82/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016(w] VOGELE Vibration page Description Operator's stand - eax + Fig.2-46: Vibration page [1] Vibration speed indication Automatic / Manual / OFF Machine data page [2] Vibration speed setpoint 7g.2-47; Machne data page [1] Distance counter reset to zero [2] Screed plate temperature indication [3] Paving distance counter indi- cation [4] Paving speed indication [5] Open service pages (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 83/253Description Operator's stand [w] VOGELE Button assignment service page 00.00.22 Fig.2-48; Button assignment service page Distribution auger material sensor service page 24.940 /D UBat 24.67 U Fig.2-49: Distribution auger material sensor service page Automated grade and slope control socket sei page NF CON 6.14} HF SEN 1.080 |E FUBat 24.99 y| c 4 UStab 8.170 STR/GND ou NF SEN 3.970 HF CON 8.15 U| GND yl woes Fig.2-50: Automated grade and slope control socket service page 84/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016M)VOGEE gent Screed heating page Fig.2-51: Screed heating page [1] Screed heating indication ON/OFF Distribution augers height adjustment page 7ig.2-52: Distribution augers height adjustment page (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 85/253Penne [w] VOGELE <= Distribution augers page Fig.2-53: Distribution augers page [1] Rate setpoint [3] Quick adjustment [2] Material sensor ON / OFF indication Conveyors page —— 8% 1—— | ea - I [+ | Fig.2-54: Conveyors page [1] Rate setpoint tt Sy] 86 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016Description Operator's stand ig. 2-55: Auxiliary control [1] Tow point ram [4] Locking [2] Sereed extending unit [5] Vertical setting [3] Slope [6] Distribution auger ‘The auxiliary control mounted on the right Is described in the following. e ‘The auxiliary control mounted on the left functions likewise. ‘Tow point ram [1] ae ih laa Rio = NIVELTRONIC Plus® inactive = Top button: right-hand side screed tow point ram is raised. ~ Bottom button: right-hand side screed tow point ram is low ered. + NIVELTRONIC Plus® active ~ Top button: The setpoint for the right-hand side tow point sen- Sor is increased. - Bottom button: The setpoint for the right-hand side tow point ‘sensor Is reduced. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 97/253Description Operator's stand lw] VOGELE S___—_Seteed extending unit £21 ‘The button has the following functions: ‘+ Right button: The seed extending unit is moved te the right. ‘+ Left button: The screed extending unit is moved to the left Sap Slope [3] ‘The button has the following functions: ‘+ Top button: the outer edge of the screed extending unit Is raised. ‘+ Bottom button: the outer edge of the screed extending unit is low- ered. Locking [4] If the diode illuminates, slope and berm (option) are flattened and inactive Vertical setting [5] ‘The button has the following functions: ‘+ Top button: Raises the screed plate of the screed extending unit. ‘+ Bottom button: Lowers the screed plate of the screed extending unit. sai acco Sonia Detaeh onion Te wns page eammerencieneaeamnasere es + Bottom button: The right-hand side distribution auger runs at DD maximum speed. 88 / 253 BAL_1382_2125422 01 en Joseph Vogele AG 2016VOGELE operators and 2.02.04 Vandalism protection ia. 2-56: Vandalism protection ‘The vandalism protection (5) protects the operator's console (1) against wanton damage end the road paver against unauthorised use. If the vandalism protection (5) Is not required, it can be hung on the left-hand seat console and locked. ‘There are concise instructions in the vandalism protection (5). The in- structions 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. joseph Vogele AG 2016 BAL_1382 212542201 en 89/253oe [w] VOGELE 2.02.05 Umbrella Fig. 2-57, Umbrella ‘The umbrella is available as an option which is fitted to the hand rails of the driver's seat. 2.03 Not used 90/253 BAL_1382_2125422_01_en © Joseph Vegele AG 20163 Description VOGELE gn / Tat gop 2.04 Engine / motor group Fig. 2-58: Engine / motor group (2) Engine compartment (4) Air intake (2.04.04) 04.01) (2) Fuel supply (2.04.02), net (5) Cooling system (2.04.05) shown (3) Exhaust system (2.04.03) (6) Diesel speed adjustment (on ‘operator's console), not shown joseph Vogele AG 2016 BAL_1382 212542201 en 91/253Description Pe wns lw] VOGELE 2.04.01 Engine compartment Fig. 2-59: Engine compartment (I) ig. 2-60: Engine compartment (1) [41 Diesel engine [3] Engine oil filler cap [2] Dipstick [4] Engine oll filter ‘The diesel engine [1] has low emissions and Common Rall injection. It has a turbocharger. 92/253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016my Description VOGELE gn / Tat gop ‘An indieation on the display shows on the operator's console if the en gine oll pressure is low. 2.04.02 Fuel supply Fig. 2-61; Fuel supply [4] Fue filler [2] Fuel cap joseph Vogele AG 2016 BAL_1382 212542201 en 93/253Description Engine / motor group wi] VOGELE Fig. 2-62: ter Fuel supply [3] Fuel pre-filter with water [4] Fuel filter trap When fillina the tank with fuel, ensure no dirt enters the tank. Never run the fuel tank empty. ‘The fuel content in the fuel tank is indicated on the display of the op- ‘erator's console. ‘The display indicates on the operator's console if the fuel level Il too low ‘or ifthere is too much water in the water trap. 94/253 BAL_1382_2125422 01 en © Joseph Vogele AG 20163 Description VOGELE gn / Tat gop 2.04.03 Exhaust system Fig. 263° Exhaust system [1] Diesel engine exhaust pipe [3] Ventilation system, exhaust pipe [2] Silencer During transport the exhaust pipes must be removed and the transport pipes must be inserted, If necessary. joseph Vogele AG 2016 BAL_1382 212542201 en 95/253ere marae [w] VOGELE Fig. 2-64: fir take [41 Air filter [2] Maintenance indicator ‘The maintenance indicator [2] shows ifthe air filter is clogged. 96 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016Description Engine / motor group Fig. 265: Combined cooler [41 Coolant filler cap [4] Intercooler [2] Sight glass [5] Hydraulic ol cooler [3] Expansion vessel with cap [6] Coolant cooler ‘The road paver has a three-circuit cooling system that cools the coo! ant, hydraulic oll and the charge air using 2 separate circuit. [After opening the bonnet, the expansion vessel [3] for the radiator Is accessible, e “The cooling system is under pressure ifthe engine is hot. joseph Vogele AG 2016 BAL_1382_2125422 01 en 97/253oreeaiael lw] VOGELE = 2.05 Hydraulic oil feed Fig. 2-66: Hydraulic oi supply () Fig. 2-67: Hydraulic ol supply (1) (4) Hydraulic tank with level (3) Pumps (2.05.03) ‘gauge (2.05.01) Pump distribution gearbox (4) Control blocks (2.05.04) (2.05.02) 98 / 253 BAL_1382_2125422_01_en © Joseph Vegele AG 2016(w] VOGELE Description Hydraulic oll feed 2.05.01 Hydraulic tank ig. 2-68: Hydraulic tank [1] Runback suction ter [31 Hydrauile ol filler cap [2] Over wi ter [4] Level gauge ‘The level in the hydraulic tank (1) must be visible on the level gauge [4] on the hydraulic tank and should be between the min and max marks. ‘The hydraulic system includes an overflow oil filter [2] and a runback suction filter [1]. Both are integrated in the hydraulic tank. 2.05.02 Pump distribution gearbox ‘The pump distribution gearbox (2) drives the pumps for the entire hy- draulic system and Is bolted to the diesel engine. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 99/253Description Hydraulic oll feed [w] VOGELE 2.05.03 Pumps Fig. 2-69: Hydraulic pump (1) i 22 (31 [4] [5] Conveyors, ventilation sys- tem Vibration Rem funetions 1 ll supply of advance drive Right advance drive ‘The ram functions I [3] include: = Screed float ‘+ Raising/lowering screed ‘+ Ralsing/lowering distribution auger ‘+ Moving entry flap (option) ‘+ Raicing/lowering hopper walls ‘+ Pressure switch valve = Levelling unit + Prassure supply ‘+ Hydraulic screed lock (option) ‘The ram functions 11 [8] Include: Retracting and extending screed Undercarriage brake [6] m7 [8] [9] Left advance drive Distribution augers Ram functions I Coil supply for distribution ‘auger, conveyors 100 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016Description Hydraulic oll feed 10 Fig. 2-70; Hand pump [10] Releasing / tensioning the [12] Hand pump for releasing the hand pump track bands brake [11] Lever ‘The hand pump for releasing the brake [12] Is required for releasing the brake. joseph Vogele AG 2016 BAL_1382 212542201 en 301 / 253ae [w] VOGELE 2.05.04 Control blocks vet \S 3 Z Fig. 2-71: Control Blocks (2) [4] Conveyors / Ventilation [3] Distribution augers [2]. Releasing / ensioning the track bands 4 4 Fig. 2-72: Control Blocks (11) [4] Ram functions 1 102 / 253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016my Description lw] VOGELE siete oytem 2.06 Electrical system Fig. 272: Electrical system (2) (2) 24V power supply (2.06.01) (4) Heating box (2.06.03) (2) Socket Fig. 2-74: Electical system (11) (3) Switch box (2.06.02) (5) Generetor (2.06.04) joseph Vogele AG 2016 BAL_1382 212542201 en 303 / 253ere [w] VOGELE ‘The sockets (2) are described in section 2.01.04, ‘There are two supply networks in the electrical system: + The 24-V DC power supply provides the engine, lighting and control ‘electronics with the necessary electrical power. ‘+ The 400 V power supply provides the screed heating, the oven, the NEMA and CEE sockets with the necessary power. 2.06.01 24 V power supply Fig. 275: 24V power supply [1] 24 V main fuses [2] 12 V starter batteries ‘The 24 V power supply (1) Is provided by the alternator of the diesel ‘engine and two 12 V starter batteries [2] connected in series. ‘The main fuses [1] provide protection for: ‘+ Switch box (125 a) = Ignition (400 A) ‘= Alternator and starter (300 A) 104 / 253 BAL_1382_2125422_01_en © Joseph Vegele AG 2016Description Electrical system Fig. 2-76: 24 V distribution box [1] Fuse strip ‘The switch box (3) contains the wiring and fuses for the 24 V attach- ments, All fuses are on the fuse strip [1]. The allocation of the individual fuses is described in section 4. Observe the following instructions: + Never mend or bridge fuses. + Always replace damaged (blown) fuses. + Ifa fuse blows repeatedly, contact an electrician, + Do not spray the distribution box with liquids. joseph Vogele AG 2016 BAL_1382 212542201 en 405 / 253Description Electrical system [w] VOGELE 2.06.03 Heating box Fig. 2-77: Exterior of heating box Warning light (red) [1]. Circuit breaker monitoring [2] Insulation monitoring unit Indicator (green) [3] Oven connection [4] Right screed heating [5] Left screed heating ‘The heating box (4) is below the right driver's seat. Ifthe driver’s seat Is pivoted outward, the heating box (4) Is accessible. ‘The sockets of the heating box are described in section (2.04.04). e Do not spray heating box with liquids. Danger due to liq is in the heating box Liquids may enter the heating box and cause damage and injury. "+ Do not spray heating box with liquids. “+ Wear personal protective equipment. + Adhere to the safety manual. 106 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016Description Electrical system Fig. 2-78: Interior of heating box [6] Circutt breakers [7] Insulation monitering unit ‘The heating box (4) contains the wiring and fuses for the 400 V screed heating, Generator and screed heating or heating rods for the screed are protected using circuit breakers [6]. ‘The following components are protected by the circult breaker (6]: + Generator + Screed heating elements, + Oven + Balloon light If the circuit breaker [6] has tripped, the circult breakers monitoring warning light [2] on the heating box (4) illuminates. Circuit breaker [6] has tripped >> Identify why the circuit breaker [6] has tripped and rectify the cause: of the fault. >> Switch cireult breaker [6] on again. If the circuit breaker (6] trips again, call an authorised electrician, Insulation monitoring unit [7] If the insulation resistance drops below a pre-set value, the indicator on ‘the heating box (4) illuminates. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 307 / 253ashen lw] VOGELE {further use the insulation fault must be rectified by an authorised ea It Is possible to continue working on this day. Nevertheless, prior to electrician. 2.06.04 Generator Fig. 2-78: Generator [1] Generator ‘The 400 V power supply Is obtained from the generator [1]. The gener- ator [1] Is driven by the pump distribution gearbox. ‘The generator [1] is a brush-less synchronous generator. Tt provides the power necessary for the screed heating and the sockets. 108 / 253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE Description Not used 2.06.05 Limp Home 2.07 Not used Fig. 2-80: Limp Home activation [4] Key switch Ifa control unit falls, the road paver can be used to @ limited extend and the engine cen be started thanks to the Limp home mode. ‘The key switch [1] in the heating box activates the Limp home mode. joseph Vogele AG 2016 BAL_1382 212542201 en 309 / 253Description Advance drive [w] VOGELE 2.08 Advance drive WL Fig. 2-81: Advance drive (4). Track band (2) Hydrostatic compact drive ‘The road paver has a hydrostatic compact drive (2). Every track band (1) has its own hydrostatic compact drive (2) which consists of @ advance drive gearbox and an adjustable motor. Risk of material damage ‘The rubber of the track bands can be damaged. "= Ensure that the rubber of the track bands do not come in con- tact with oll or fuel. ‘On both eraviler track gearboxes there is @ hydraulically releasable spring-actuated multiple disc brake that locks the gearbox when the diesel engine is suitched off to prevent unintentional rolling away / movement of the road paver. The brake locks the gearbox immediately after the enaine Is shut down, [After starting the engine, the spring-loaded multiple disc brake Is auto- matically released by the hydraulic system and allows driving on. The ‘spring-actuated multiple disc brake is coupled to the main drive switch (position P). 310/253 BAL_1382_2125422 01 en © Joseph Vegele AG 2016VOGELE ssesteg spa 2.09 Steering system Fig. 242: Steering system (2) Direction indicator ‘The diraction indicators (1) halp the operator to keep to the paving line. ‘The direction indicator [1] must be removed during transport. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 441 / 253Description Conveyor unit [w] VOGELE 2.10 Conveyor unit 1 Fig. 28%: Conveyor unit (0) (GQ). Push roller (3) Conveyors (2.10.02) (2) Materiel hopper (2.10.01) (4) Support for push rollers ‘The road paver moves and pushes the truck forward with the push rell- ‘ers (1). During this process the push rollers (1) are in contact with the tyres on the truck. ‘The push roller (1) has three positions: basic setting and two further ‘settings (2 inch / 50 mm und 4 inch / 100 mm). 442/253 BAL_1362 2125422 01_en © Joseph Vagele AG 2016Description Conveyor unit Fig. 2-84: Conveyor unit (11) (5) Distribution augers (2.10.03) ‘The mix Is dumped from the truck into the material hopper (2). The conveyors (3) move the mix to the distribution augers (5), which dis~ ‘tribute the mix evenly in front of the screed. © Joseph Végele AG 2016 BAL_1382 212542201 en 413 / 253Description Conveyor unit [w] VOGELE 2.10.01 Material hopper Fig. 285: Material hopper [4]. Entry flap [4] Hopper wal locking [2] Hopper wait [5] Material stike-off plates 3] Adjustable material stike-off plates ‘The material hopper (2) Is used for storing the mix. Entry flap [1] and material strike-off plates [3], [5] prevent the mix falling onto the base. ‘The hopper walls [2] can be raised and lowered separately or together Using hydraulics. Entry flap versions ‘= Mechanically folding (e.g. for maintenance) During paving remains the material on the entry flap. ‘+ Hydraullcally adjustable (option) Prevents material from dropping out when the material hopper (2) Is. closed. During transport or menoguvring on the construction site, the hop- per walls [2] must be relsed end locked. 114/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016Description Conveyor unit, 2.10.02 Conveyors Drive units Fig. 286: Left conveyor drive units [1] Right conveyor drive unit Both conveyors (3) have thelr own drives. The drives comprise @ hy- > Use an assistant if there are areas around the machine which are hard for you to see. 136 / 253 BAL_1382_2125422 01 en Joseph Vogele AG 2016operation iw] VOGELE Placing the road paver In eperation Starting the engine PLU Tiss Danger due to heavy load “The road paver may roll away / move unintentionally and can cause fatal Injuries. ‘Prior to starting the road paver, ensure there Is nobody in the hazard area. Secure site around the road paver, erect barriers. Starting the engine >> Set operating mode selector switch to NEUTRAL and main drive ~ switch to position P. >> Turn ignition key to position 1. v System boots. >> Walt until the start page appears on the display. >> Place main drive switch [8] in position P, see section 3, >> If necessary, unlock emergency stop buttons [1] and [7] by turning clockwise, see section 3. >> Press start / switch off engine button [31] for 30 seconds maximum, see section 3. If the button is pressed for more than 30 seconds wait at least two minutes before re-starting. The engine starts. >> Release start / switch off engine button [31], see section 3. The engine runs at idle. e Allow engine to idle for approx. ten minutes. Risk of poisoning due to exhaust fumes Exhaust fumes from diesel engines place your health at risk and ‘can cause life-threatening ilinesses, ‘+ Observe instruction labels on the road paver. ‘© Only run the engine in well-ventilated places. + In enclosed places lead off the exhaust fumes to the outside. ‘Warm up road paver (heat screed and prepare units) ‘The warm-up time is approx. 20 minutes, press heating button [20], see section 3, © Joseph Végele AG 2016 BAL_1382_2125422 01 en 137 / 253Operation Papen RNC Eset [w] VOGELE Risk of crushing Being drawn in the convayers / distribution augers causes serious Injuries or fatality. If you press button [4], the conveyors and distribution augers start working, + Ensure there are no people or objects in the hazard area. + Ensure the safety devices are fully fitted. Switching on and off con- >> Press button [4], see section 3. weyers / distribution at conveyors and distribution augers stert cunning GEIS) The diode in the button illuminates. oO >> Press button [4] again, see section 3, Stop conveyors and distribution augers. The diode in the button goes off. 3.01 Driving, stopping and turning the road paver PY) Danger due to heavy load ‘The road paver may roll away / move unintentionally and can cause fatal injuries. + Prior to starting the road paver, ensure there is nobody in the hazard area. + Secure site around the road paver, erect barriers. 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 station ary. PY Danger due to unintentional rolling away / movement ‘The road paver 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 the neutral position, + Shut down engine and remove ignition key. 138 / 253 1822125422 01_en © Joseph Vogele AG 2016VOGELE Driving the road paver (paving) e Driving the road paver (manoeuvring, position- ing) e ‘Stopping the road paver according to schedule ‘Turning the road paver on the é oO Operation Driving, stopping and turning the road paver If the main drive switch [8] is actuated, the road paver starts to move after a brief delay, see section 3, >> Set operating mode selector switch to paving. >> Select diesel speed using diesel speed adjustment [30], see sec- tion 3. >> Adjusting the speed range with control knob for paving speed [6], ‘see section 3. >> Select speed using the main drive switch [8], see section 3. Posi- ton F Is maximum speed with respect to the preset speed range. ¥ The road paver pulls away. Ifthe automatic diesel speed adjustment Is active and the main drive switch [8] Is in position P, the LED flashes, see section 3. “The paving speed must not be changed during paving. >> Set operating mode selector switch to positioning. >> Select diesel speed using diesel speed adjustment [30], see sec- tion 3. >> Select direction of travel and speed using the main drive switch [Bs], see sectiun 3 = Position F for driving forward. = Position R for driving backward. ¥ The road paver pulls away. ‘The road paver is steered using the steering joystick. >> Place main drive switch [8] in position P, see section 3, ¥ The road paver Is stationary and secured against unintentional roll- Ing away / moverient. ‘The road paver can be stopped independently of the operating mode. Precondition: Main drive switch [8] Is in position P, see section 3. >> Keep Lullun [5] pressed, see section 3, >> Move steering joystick [28] to left or right, see section 3. >> Adjust the speed using the steering joystick [28], see chapter 3. ¥ The road paver turns to the corresponding direction. >> Release button [5], see section 3. The road paver is stationary. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 339/253Operation Laying pavement lw] VOGELE 3.02 Laying pavement ‘The rising and descending screed can cause fetal injuries. ‘+ There must not be any people under the screed. 3.02.01 Unlocking and lowe! g hopper walls Fig. 32: Hopper wall ocking [1] Locking clip [3] Pin [2] Handle Py tas) 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. + Ensure the safety guards of the conveyors are fully fitted. ‘+ Observe instruction labels on the road paver. 140 / 253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE Laying pavement Danger due to hot surfaces Parts of the material hopper are very hot - risk of injury! "+ Wear personal protective equipment. = Donnot touch any parts of the machine if possible. >> Pull locking clip [1] from the pi >> Push out pin [3] In the gate using the handle [2]. ‘The pin must not be in the opening of the chassis. >> Lower hopper walls. >> Secure pin [3] with locking clip [1]. ¥. The hopper walls have been unlocked and lowered. e How to lock the hopper walls is described in section 3.05.03. 3.02.02 Lower distribution auger "ig. 3-3: Hydraulic distribution auger height adjustment [1] Hydraulic distribution auger height adjustment >> Lower distribution auger. ‘With the distribution auger in lowest position a minimum ground clearance (between ground and auger blade) must be maintained. The distribution auger Is lowered. joseph Vogele AG 2016 BAL_1382 212542201 en 441 / 253Operation eco iassaccmigenee [w] VOGELE ‘The distribution augers together with the limiting plates and the } supports can be adjusted in height across the entire working width. IY) Risk of trapping and crushing Reaching in the rotating distribution augers causes serious injuries and/or death. + Observe instructio labels on Ue road paver "+ Do not reach into rotating parts. + Do not wear loose clothing or jewellery. + Ensure the safety devices are fully fitted. * Extended distribution augers must be equipped with limiting plates across the entire working width. ‘The auger blades are designed for working approx. 1.57 inch / 40 mm above the bottom edge of the screed. 3.03 Manoeuvring the road paver Tusk ot falling Risk of falling due to moving machine. This can cause serious inju- res or even death. + Prior to manoeuvring ensure that there are no persons on the road paver or the screed. + The road paver may only be manoeuvred if the operator is on the driver's seat. + Only use the floor to cross the screed with the machine station- ary. “The manuavering operating mode must be selected for maneuvering the machine. During transport, loading or manoeuvring on the construction site, the distribution auger must be in ts highest position. os 142 / 253 1822125422 01_en © Joseph Végele AG 20167] VOGELE operation Manoeuvring the road paver PY. Danger due to heavy load ‘The road paver may roll away / move unintentionally and can cause fatal injuries. + Prior to starting the road paver, ensure there Is nobody In the hazard area. + Secure site around the road paver, eract barriers. 3.03.01 Raising / lowering the screed and locking ‘Warning of crushing hazard Retracting and extending parts of the machine or parts of the ma~ chine moving up and down can cause fetal injuries. + Ensure there are no people or objects in the hazard area. + Ensure the safety devices are fully fitted. Risk of damage to the screed The screed may sink and be damaged if + the paving operating mode is switched on. + the screed is or has been moved. Risk of falling With the screed raised, the first step can be higher than 24 inch / 1600 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. A LB ee A Raising / lowering the >> Unlock screed if necessary (ralse screed and retract locking pins). screed >> Keep middle or bottom button [17] pressed, see chapter 3. p< The screed moves to the related direction. >> Release middle or bottom button [17], see chapter 3. ¥ The screed remains in its position. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 143 / 253Pisani ptm poner [w] VOGELE Mechanically locking the screed Fig. 3-4: Mechanically locking the screed [4] Pin [3] Handle [2] Gate Mechanically locking the Precondition: screed — Crown, planing angle and slope are set to 0%, ~ Screed is raised to its highest position. >> Pull pin [1] up using handle [3] to the stop. >> Pull out pin [1]. >> Press down handle [3]. ‘The handle [3] must be securely engaged in the gate [2]. >> Lower screed. The tow point arms are securely in contact with the pins. The screed has been locked mechanically. a ‘Always secure screed on both sides of the road paver. Locking and unlocking the Precondition: teed hydraulically Crown, planing angle and slope are set to 0 %. Je Screed is ralsed ta Its highest position. >> Press upper button [17], see section 3. ¥ Both locking pins are extended. The diode in the button illuminates, see section 3. >> Keep bottom button [17] pressed. 144 / 253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE Operation Cleaning and shutting down the road paver The tow point arms are securely in contact with the pins. >> Release bottom button [17], see chapter 3. The screed has been locked mechanically. “The screed is unlocked in the reverse order of locking 3.04 Cleaning and shutting down the road paver Cleaning the road paver Danger due to hot surfaces Parts of the material hopper are very hot - risk of injury! + Wear personal protective equipment. = Donnot touch any parts of the machine if possible. ‘Warning of crushing hazard Conveyors and distribution augers run at moderate speed in the cleaning mode and can cause fatal injuries and death. © Observe instruction labels on the road paver. + Donot reach into rotating parts. + Donot wear loose clothing or jewellery. © Ensure the safety devices are fully fitted. Allow material hopper, conveyors and auger compartment to run empty before you clean the machine, When working on the open material hopper, park road paver on firm, level ground, 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 auger Front well, frame (screed plate) and compaction system of the ex- tending screed (see screed operating instructions) Push rollers ‘Track bands, track rollers, drive and guide wheels © Joseph Végele AG 2016 BAL_1382_2125422 01 en 445 / 253Oper: Camry and hang doth rd poe: lw] VOGELE -ACAUTION Risk of material damage ‘The rubber of the track bands can be damaged. * Do not clean track bands with release agents that contain oll, petrol, diesel or kerosen + Clean track bands with soap and hot water. 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 rnot inhale vapours. ‘+ Wear personal pretective equipment. + Read and observa instruction in the related data sheets. >> For bituminous mix, use bitumen solvent. >> In case of concrete paving, clean the parts of the machine listed ‘above with a water jet. Open bearings and grease nipples must not directly be subjected to the water jet. Risk of crushing Being drawn in the conveyors / distribution augers causes serious injuries or fatality. If you press button [4], the conveyors and distribution augers start working. + Ensure there are no people or objects in the hazard area. + Ensure the safety devices are fully fitted. ‘Switching on and off con- >> Press button [4], see section 3, veyors / distribution au- / Conveyors and distribution augers start running. Sey The diode in the button illuminates. >> Press button [4] again, see section 3, ©? stpcomeyors and dritin sizes ¥ The diode in the button goes off >> Leave conveyors and distribution augers to run in the cleaning mode ‘and spray thoroughly to prevent material adhesion. >> Collect used release agent In a sultable container as necessary. Release agent / bituman mixture may not be released Into the envi- ronment. >> Dispose of left over release agent correctly to protect the environ= ment. 146 / 253 BAL_1382_2125422 01 en Joseph Vogele AG 2016operation iw] VOGELE Clearing and shutting down the road paver If this cleaning work is not performed, material will become bonded to the moving parts and as a result the functions degrade. Premature wear and tear of the drive and conveyor elements will be the consequence, Shutting down the road paver Oa Danger due te full braking Risk of injury in case of incorrect operation. + Prior to operating the main drive switch, turn the control knob for paving speed to position 0. Danger due to emergency stop If the road paver is stopped using the emergency stop button, ~ Mechanical parts are subject to increased wear, = Electrical and hydraulic components may be damaged. + Only use the emergency stop button in case of danger. + Dornot use the emergency stop button to stop the road paver Under normal circumstances. Risk of material damage ‘The rubber of the track bands can be damaged. + Donot park the road paver on hot asphalt. + Donot park the road paver on curbstones. + Cover the track bands, if the road paver is stored outside. >> Place main drive switch [8] in position P, see section 3, >> Remove any mix stil in the road paver. >> Clean the road paver. >> Place operating mode selector switch In the neutral position. >> Set diesel speed adjustment [30] to MIN setting, see section 3, >> Switch off screed heating [20], see section 3. >> Switch off screed functions and all conveyor and compaction sys- tems. >> Lock hopper walls. >> Lower screed. Do not shut down engine immediately after operation at full load. Leave to run engine at idle for 3 to S minutas to allow time for tam- perature equalisation. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 147 / 253Camry and hang doth rd poe: lw] VOGELE > Switch off engine. Press starting / shutting down engine button [34] for approx. 2 seconds until the engine stops, see chapter 3. >> Turn ignition key In the ignition lock [7] te position 0, see section 3. >> Remove ignition key. >> Pivot in and secure eperator's console. >> Pivot back pivoted out driver's seat, check engagement. >> Secure operator's console and outer control stands with the vandal sm protection. >> Remove sensors and stow away. >> Insert extendable shelves / bracket. The road paver has been shut down. Joseph Vogele AG 2016 348 / 253 BAL_1382_2125422 01 enlw] VOGELE Operation ‘Transporting / loading the road paver 3.05 Transporting / loading the road paver ig. 3-5: __Lashing and lifting points Fig. 3-6: Botton lifting points [1] Rear lifting points [3] Front lifting points [2] Lashing points ‘The applicable health and safety regulations such as UVV, DIN, VDI and national regulations are to be observed. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 349 / 253Operation Transporting / leading the roed paver lw] VOGELE Psa Danger due to heavy load ‘The road paver can slide or tip - risk of fatal injuries. + In case of crane leading, observe lifting points and operating ‘weight of the road paver. + Read safety manual. + Observe instruction labels on the road paver. + Dornot walk or stand in the hazard area. Danger due to excess width or excess height Excess width or excess height can cause property damages end injuries. + Remove all attachments. + Pivot in driver's seats completely and secure. Preparation: Loading the >> Free track bends of coarse soiling road paver >> secure all loose pats (e.g. boxes, trim panels). >> Retrect sereed extending unt. >> Remove screed extension (separate screed opereting instructions). > Set crown, planing angle and slop of the screed to 0 6, >> Remove all attachments. >> Reise screed and lock Risk of falling With the screed raised, the first step can be higher than 24 inch / 600 mm. Risk of falling. |= When entering the machine, step carefully and hold on to the brand rails with both hands. + Never jump off the machine. >> Removing the direction indicator >> Place distribution auger in the highest posit >> Raise hopper walls and lock. 150 / 253 BAL_1382_2125422_01_en © Joseph Vagele AG 2016lw] VOGELE Tatapertiy losing the ee paver: a Fig. 3-7: Silencer with exhaust pipes [4] Transport pipe Diesel en- [5] Transport pipe Ventilation gine ystem 20 It necessary remove silencer exhaust pipes and incert transport pipes [4] and [5]. Danger due to hot exhaust pipe The exhaust pipe is very hot - risk of injury! + Wear personal protective equipment. + As far as possible, do not touch any part of the exhaust pipe. >> Pivot in and secure operator's console. >> Pwvot in driver's seats completely and secure. >> Insert extendable shelves / bracket. The road paver Is prepared for loading. a ‘The individual actions are described in the related sections. joseph Vogele AG 2016 BAL_1382 212542201 en 351/253Tepe Nosy Sonn lw] VOGELE PY sa Danger due to unintentional rolling away / movement ‘The road paver 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 the neutral position. + Shut down engine and remove ignition key. Risk of material damage ‘The rubber of the track bands cen be damaged. + Donot tum at the end of a ramp / gradient. Driving/ lashing the road >> Use strong loading ramps of sufficient width that are secured in paver on alow loader position. >> Free loading ramps of soiling (2.9. oll, snow, ice), >> Furnish loading ramps with slip-free covering. >> Observe maximum allowed ramp angle (14). >> Drive road paver on straight. >> Unlock screed and lower evenly onto the low loader. >> Shut down the road paver. >> Lash road paver to the low loader. The road paver has been driven onto a low loader and lashed down. Loading the road paver >> After shutdown, suspend the road paver only at the lifting using a crane points [1] and [3] 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. >> Load road paver using a crane, >> Remove lifting gear from the lifting points [4], [3]. >> Pivot in driver's seats, The road paver has been loaded with a crane. 152 / 253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE Trareperig ey tie paar 3.05.01 Locking the hopper walls Fg. 3-8: Hopper wall locking [1] Locking clip [3] Pin [2], Manele >> Raise hopper walls. >> Pull locking clip [1] from the pin. >> Push out pin [3] in the gate using the handle [2]. ‘The pin must be in the opening ofthe chassis. >> Secure pin (3] with locking clip [1]. ¥ The hopper walls have been locked. e How to unlock the hopper walls Is described In section 3.02.01. PPTs 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. © Joseph Végele AG 2016 BAL_1382 212542201 en 153 / 253Operation Towing the reed paver lw] VOGELE Danger due to hot surfaces Parts of the material hopper are vary hot - risk of injury! ‘+ Wear personal protective equipment. * Donot touch any parts of the machine if possible. 3.06 Towing the road paver ‘To tow the road paver + The advance drive must be switched to free circulation. ‘+The brake must be released using the hand pump and then reac- tivated after towing. ‘The road paver must not be towed more than 985 ft / 300 mm. The maximum towing speed must not exceed 33 ft/min / 10 m/min. Ny lclais Danger due to heavy load ‘The road paver may roll away / move unintentionally and can cause fatal injuries. * Ensure there are no people in the hazard area. + Wear personal pretective equipment. + Secure road paver against unintentional rolling away / move~ ment. + Secure site around the road paver, erect berriers, + Only tow using suitable vehicles, pay attention to weight of m: chine. = Only tow using towing ba 154 / 253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE sonny tes reaipate ‘Switching the advance drive to free circulation Fig. 3-9; Hydraulic pumps [1] Left advance drive [3] Right advance drive [2] Hex socket screw Switching the advance >> Secure road paver against unintentional rolling away / movement. drive to free circulation >> shut down diesel engine. >> The hex socket screw [2] of the two advance drive pumps are re- leased by 2% turn. The advance drive has been switched to free circulation, joseph Vogele AG 2016 BAL_1382 212542201 en 155 / 253Operation Towing the road paver [w] VOGELE Releasing and activating the brake Release brake Activating the brake Fig. 3-10: Hand pump [4] Lever [6] Pressure gauge [5]. Bell valve [7] Hand pump >> Secure road paver against unintentional rolling away / movernent. >> Place ball valve [5] in vertical position, >> Insert lever [4] In the receptacle on the hand pump [7]. >> Release brake by pumping. >> Observe pressure indication on the pressure gauge [6]. Increase pressure to 726.75 psi / SO bar. >> Remove lever [4] and insert in the bracket. The parking brake has been released and the road paver can be moved es required. >> Tighten the hex socket screws [2] of the advance drive pumps. >> Place ball valve [5] in vertical position. >> Place main drive switch [8] in position P. Precondition: There Is no fault in the hydraulics. The brake has been reactivated and the road paver secured against Unintentional rolling away / moving. 156 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016Operation g —_ ERE Homriictevansi) Fig. 3-41: Limp Home activation [41 Key switch [2]. Button Ife control unit falls, the engine can be started and, depending on the fault, the road paver can be used to 2 limited extend, Precondition: The following functions must be available without limita~ tion: > Emergency stop circuit + Battery charging and battery voltage + Ignition lock = Engine and engine electronics >> Turn ignition key of road paver in the key switch [1] to position 1. ¥- Limp Home is activated, >> Turn Ignition key of road paver in the lock of the operator's console to position 1. >> Operating eyetem starts. The display of the operator's console indicates the related warn- ing/fault message. The road paver is set to Positioning mode, all automatic functions are inactive. >> Actuate button [2]. ¥ The engine starts. ¥ Engine runs at 1,800 rpm. joseph Vogele AG 2016 BAL_1382_2125422 01 en 4357 / 253Operation Limp Home Activation lw] VOGELE Driving the road paver >> Depending on the fault that has occurred in the contrel system, the machine can be riven Perform the following steps to drive the road paver: >> Move main drive switch slightly in the desired direction of travel. >> Adjust the operating mode by actuating the operating mode selec- tor switch, The road paver starts immediately to move in the direc- tion and at the speed which has been set by the position of the main drive switch, >> Using the main drive switch you can set the speed and stop the road paver. >> To set the road paver in motion again after a stop, repeat the steps given above, ¥ The speed Is limited to approx. 30 ft/min / 8 m/min. Switching off the engine >> Actuate the emergency stop button [1], [7]. The engine is switched off. @ Depending on the fault in the control system, other paver functions may be available via the operator's console and the outer control stand. 158/253 BAL_1382_2125422 01 en Joseph Vogele AG 20162 operation VOGELE Cpersting the NIVELTRONTC Plus® components (option) 3.08 Operating the NIVELTRONIC Plus® components (option) Ski Wiring / sensor assignment Fa. 12; Big Sw [1] Sensor connectors [4] CAN cable with 2 x 120 R bbus terminating resistor [2] Standard CAN cable [5] Machine connection cable, analogue signal [3] Sonic ski CaN Joseph Vogele AG 2016 BAL_1382 212542201 en 159/253Operation porating tha NIVELTRONIC Plus components (opton) iw] VOGELE Indications and keyboard Fig. 3-13: Big Ski control electronics [6] Display, sensor message [10] Calibrate sensor (ico) [7] Sensor assignment (LED) [14] Call parameters [8] Seanning mode (LED) [12] Change paremeters [9] Select scanning mode call parameters >> Opan parameters [11]. >> The value conforms tothe admissible measuring range ofthe sen- sors around the calibration point (value 6 = + 1.2 inch [30 mm). Admissible operating window of the sensors is indicated on the dis- play [61- >> Change parameters or deactivate the area [12]. = Change parameters: between 4 and 20 in 0.4 inch / 40 mm steps. ~ Deactivate the range: greater than 20 = off. The parameter has been opened and changed. @ Only the parameter window is active at the moment. 160 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016() VOGELE Operation Operating the NIVELTRONIC Plus® components (option) Detecting a sensor SEn| i-3 En ro) SEn Fig. 3-14: Detecting a sensor + The sensor connectors used are Indicated by the LEDs of the sensor assignment [7] and on the display [6] + Sensor constellation or fault messagas are also indicated on the dis- play [6]. Acknowledging the sensor Ifthe Big ski has been connected for the first time or the sensor combi- nation has been changed, the sensor detection must be acknowledged. ‘The indication on the display [6] flashes. >> Acknowledge sensor detection with any button. The indication on the display [6] illuminates permanently. Setpoint calibration ‘The sensors must be calibrated to the reference before each operation (the analogue output signal is set to 4 V). >> Press sensor calibration button [10]. ¥ Setpoint is calibrated. "Set" Is indicated on the display. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 361 / 253Operation (Operating the NIVELTRONIC Plus® components (option) lw] VOGELE Scanning mode selection LeDingicator [scamming mode UCD indication Mean value formed from all 1 2 [ss*] three connected sensors Only the middle sensor is lsee| used for scanning [Sg0] String line scanning using the sensor connected in the middle Ground scanning using the a ‘Sensor OUT ‘Control window Sensor defect*™ Error 2* sensor connected In the middle Tab. 3-1: Indication of scanning mode >> Press Select scanning mode button [9] to switch between the indi- ‘vidual modes. Error messages ‘Sensors are connected to all three con- Nectors; sensor 4 and 3 are outside the physical measuring range. Sensors are connected to all three con- nectors; sensor 3 has a control window alarm. ‘Sensors are connected to all three con- ectors; sensor 1 Is signalling a fault. Loss of data in the battery backup memory. Loss of data in the paramaters saved in a memory powered by an external power ‘supply unit. Tab. 3-2; Error messages [23 SEn "| [SER "711 SER [") SEn {-3 out All fault messages will result in a 0 V analogue signal. * Alarm output is activated. 162 / 253 BAL_1382_2125422 01 en Joseph Vogele AG 2016VOGELE Operation Operating the NIVELTRONIC Plus® components (option) 3.08.02 Ultrasonic sensor Fig. 3-15; Ultrasonic sensor with working area [4] LED [2] Working area Risk of damage to the machine “The reference bail can get stuck and break, + Be careful curing operation. Ensure the reference bail does not get stuck, The ultrasonic sensor has a working range of 11.8 inch / 300 mm to 23.6 inch / 600 mm. The recommended working range of 13.8 Inch / 350 mm to 21.7 inch / 550 mm. Within this range the status LED Is continuously Illuminated. If the sen- sor is outside the working range, the status LED flashes. EI cr < 11,0 Inch / 300 mm flashes quickly (40 Hz) 414.8 to 13.8 inch / 300 to 350 mm flashes slowly (2 Hz) 413.8 to 21.7 Inch / 350 to 550 mm iluminates 21.7 to 23.6 inch / SSO to 600 mm fleshes slowly (2 Hz) > 23.6 inch / 600 mm ffashes quickly (10 Hz) Reference bail eror flashes quickly (10 Hz) Tab. 3.3: Working range ofthe ultrasonic sensor © Joseph Vegele AG 2016 BAL_1382 2125422 01 en 163 / 253,Oper: porating tha NIVELTRONIC Plus components (opton) [w] VOGELE 164 / 253 BAL_1382_2125422_01_en Joseph Vogele AG 2016VOGELE Maintenance Special safety instructions 4 MAINTENANCE 4.00 Special safety instructions Maintenance work that must be organised or performed is described in this section. The capacities and service interval are given in the mainte- nance schedule in section 5.01. ‘The specification of greases and olls is described in the lubricant chart in section 5.03. 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 nec- essary! The tightening torques are given inthe tightening torque chart in section 5.02. 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 cling com- ponents and parts. {All maintonanee and repair work described in this section is only allowed to be performed by personnel who have been trained by Vegele. This works include repairs to the hydraulic, electrical and brake systems as well as to the engine. Observe the service check booklet and follow the service intervals according to these operating instructions. So the claims under warranty will remain. Observe following safety instructions: + Repair, care, maintenance and cleaning work as well as the recifica- tion of malfunctions are solely to be undertaken with the engine sta- tionary! + Secure road paver against unintentional placing In operation and rolling away. + Park road paver on firm, level ground. + Remove ignition key + Observe safety instructions to avoid injuries and accidents. + Attach warning to operator's console. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 365 / 253Maintenance Chassis /safety devices lw] VOGELE 4.01 ‘+ Hydraulle pipes are to be replaced at the latest after six years (In- cluding a storage period of max. two years). + Only use original Vogele filters and grease, filters from other manu- facturers may cause damage to the engine, ‘+ Place old filter in a suitable container to collact escaping waste oll or fuel ‘+ Dispose of filters, weste oll, uel, release agent and grease correctly ‘and with due care for protecting the environment, /safety devices Perform the following service work: “+ 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 light ~ Brackets for the bonnet ~ Piston rods on the gas struts of 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 oll leaks. If the foree Is reducing or oll Is escaping, replace gas struts. ‘+ Minor damage, corrosion or paint residue on the gas strut piston rod will result i the failure of the strut, the seals will be damaged. “+ Check warning feature; for example on extending the screed to the left, the warning light on the let outer control stand must flash; on driving the road paver backward an acoustic warning must be audi- ble (option). ‘+ Check emergency stop button, horn and beacons (option) for correct function. ‘+ Check lighting for demage and replace if necessary 166 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE (Giants oat Sons 4.01.01 Ventilation system Cleaning air slots Fig. 4-1; Air slots at the conveyor compartment [11 alr siots [2] Conveyor compartment >> Check air slots [1] at one end of the conveyor compartment (2] and clean if necessary. joseph Vogele AG 2016 BAL_1382 212542201 en 367 / 253Maintenance Operator's stand [w] VOGELE 4.02 Operator's stand Fig. 4-2: Pivoting bearing on the driver's seat [41 Pivoting bearing Perform the following service work: >> Keep steps, hand ralls, platforms and grids dry and clean, >> 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. i) “The film on the operator's console may become detached. >> Clean operator's console only with a special cleaning, see ‘maintenance chart. Ifa different cleaning agent is used, the warranty will be void. 4.03 Not used 168 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 20162 Maintenance VOGELE Engine / motor group 4.04 Engine / motor group 4.04.01 Engine compartment 4.04,01.01 Changing the engine oil filter ig. 4-3: Engine oll ter [4] Engine oll iter Danger due to hot engine Parts of the engine can be very hot - risk of injury! + Wear personal protective equipment. + As far as possible, do not touch any part ofthe engine. Changing the engine oil Preconcition: Engine oll hes been drained (4.04.01.03). Titer’ >> open engine maintenance fiap. Y ‘The engine oil iter [1] ls accessible. >> Place a suitable container undemeath the engine ol fiter [3] to col- lect draining ol. >> Undo engine cil filter [1] using a strap wrench, unscrew and dispose of with due care forthe environment. > Wipe up any ol that escapes using an absorbent cloth and dispose of with due care forthe environment. >> Clean the sealing surface on the filter carrier using a clean, fluff-free cloth. >> Slightly oll seal on the naw angine oll filter. joseph Vogele AG 2016 BAL_1382 212542201 en 169 / 253ee fs) VOGELE > Fill new fiter [1] with engine oil, >> Screw on engine cil ter [1] by hand until the seal isin contact. > Tighten engine oil fter [1] by %4 of a turn, > Fill with engine oil (4.04.01.03). >> Place road paver fora brief period in operation and check sealing surfaces for leaks. >> Manually checking the engine cil level (4.04.04.02). >> Close engine maintenance flap. The engine oil filter has been changed. 370 / 253 BAL_1382_2125422 01 en Joseph Vogele AG 2016Maintenance VOGELE Engine / motor group 4.04.01.02 Checking the engine oil level Tig. 4-4 Engine compartment [1] Dipstick CCheck engine cil level prior to every time the machine is used. Manually chacking the Only check engine oll level when engine is cold and stationary; I the engine oil level engine is warm, wait five minutes. >> Shut down roed paver and remove ignition key. >> Open engine/fuel fier maintenance fap. The dipstick [3] Is accessible. >> Pull out dipstick [1] and wipe with a clean, fluf-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 nec essary. >> Re-insert clpstick [1] to the stop. > Lock engine/fvel filter maintenance flap. Engine oll level has been checked manually. joseph Vogele AG 2016 BAL_1382 212542201 en 471 / 253ae uy] VOGELE 4.04.01.03 Changing the engine oil Fig. 45: Ol drain hose Fig. 4-6: Engine compartment [1] oll drain hose [2] Engine oll filler cap ‘The engine oil filter must always be changed when the engine oil is changed. 372/253 BAL_1382_2125422_01_en © Joseph Vogele AG 20167] VOGELE Maintenance Engine / motor group 19 the engine The oll must be in at operating temperature. An oll drain hose [1] is fitted to the sump, ‘The oll drain hose is laid on the right-hand side of the road paver in the direction of travel and is fastened below the advance drive pump. >> Shut down road paver and remove Ignition key. >> Open right side trim panel. CAUTION Danger due to hat ot Oi eran owe, and parts onthe engine can be vry hot =k of mee + Wen persona prtetveeaupment. reece reer ree Ue caren eerioment! + incaoe of nkes, soak Irmdlte rela otnton ‘The oil drain hose for the engine cil is next to the cil drain hose for the gearbox oil and the hydraulic oil drain hose. Do not mix up oi drain hoses. For safety reasons trace back the hoses. >> Undo fastening clip. >> Have a suitable container at hand, note capacities. >> Open the bonnet. Danger due to hot engine Parts of the engine can be very hot - risk of Injury! ‘Wear personal protective equipment. + As far as possible, do not touch any part of the engine, The engine oll filler cap [2] Is accessible. >> Open engine oll filer cap [2]. >> Guide cil drain hose [1] into the container. >> Undo sealing plug using a suitable tool. >> Completaly drain oll. >> Mount and tighten sealing plug. > Lay oll drain hose [1] without kinks and secure with fastening clip. >> Dispose of waste oil with due care for the environment, The engine oll has been drained. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 173/253,Maintenance Engine / motor group lw] VOGELE 19 the engine 1 >> Add fresh oll vie engine oll filler cap [2], use @ funnel as an aid. >> Fill sump with engine oll to the Max mark on the dipstick. >> Close engine oil filer cap [2]. >> Leave engine to run for a short time, >> Manually checking the engine oil level (4.04.01.02).. >> Close bonnet. The engine has been filled with oll, 4.04.02 Fuel supply Risk of damage to the machine ‘The fuel system Is very sensitive and can be damaged by solling. + When working on the fuel system, pay attention to cleantines: * Clean area around the related parts. + Dry damp areas using compressed Danger due to system under pressure ‘The fuel system Is prassurised; danger of fatal Injury! + Shut down engine and remove ignition key. + After shutting dovin the engine, wait 1 minute until the pres- sure has dissipated. "+ Do not work on the fuel pipes of the engine. ‘+ Never undo high pressure pipes (Injection system pipes). 174/253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016Maintenance VOGELE Engine / motor group 4.04.02.01 Fuel pre-filter ig. 4.7; Fuel pre-ter with water rap [1] Fuel pre-filter with water trap [3] Connector [21 Drain valve [4] Hand pump Drain water from fuel pre-filter [1] when @ 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 healt ‘Wear personal safety equipment (safety gloves). © Donot smoke, no naked flames. Only work on the fuel supply when the diesel engine is cold and shut down. Draining the fuel pre- > Shut down roed paver and remove ignition key. filter >> open engine/fuelfiter maintenance flap. ¥ The fuel pre-fter [1] is accessible, >> Place a suitable container under the fuel pre-fiter (1). >> Open the drain vaive [2] and drain the liquid. > Observe the draining process and close the drain valve [2] on transi= tion from water to fuel. > Dispose of liquid with due care for protecting the environment. joseph Vogele AG 2016 BAL_1382_2125422 01 en 175 / 253Maintenance Engine / motor group lw] VOGELE Changing the fuel pre~ filter >> Start engine and check the system for leaks. The fuel pre-filter has been drained. Risk of damage to the machine Engine can be damaged. "© Do not fil fuel in the filter before It Is mounted. + Mount only empty fuel filter. >> Shut down road paver and remove ignition key. >> Open engine/fuel filter maintenance flap. ¥ The fuel pre-fiter [1] Is accessible. >> Disconnect the connector [3] for electric monitoring. >> Place suitable container under the fuel pre-filter [1] to collect the es- eaping fuel. >> Open the drain valve [2] and drain the liquid completely. >> Undo fuel pre-filter cartridge and water trap using a strap wrench. >> Dispose of fuel pre-fiter cartridge and water trap with due care for the environment. >> Drain the remaining fuel in the container. >> Wipe up any fuel that escapes using an absorbent cloth and dispose of taking dua care for the protection of the environment. >> Clean the sealing flanges of the filter carrier and the mating face of the filter. >> Slightly oll the seal of the new fuel pre-flters or moisten with diesel. >> Screw on new empty fuel pre-fiter cartridge by hand until the seal is In contact. >> Tighten fuel pre-fiter cartridge by % of a turn. >> Bleed fuel pre-filter with the hand pump [4]. >> Fit the connector [3] for electric monitoring. >> Lock engine/fuel filter maintenance flap. The fuel pre-filter has been changed. 176 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE Maintenance Engine / motor group 4.04.02.02 Repl 19 the fuel filter Fig. 48; ‘Fuel iter [1] Fuel fitter Danger due to incorrect handling of fuel Fuel and fuel fumes are inflammable and are harmful to your health. * Wear personal safety equipment (safety gloves). © Donot smoke, no naked flames. Risk of damage to the engine ‘The fuel system Is very sensitive and can be damaged by solling. + Donot fill new filter cartridge with fuel. Replacing the fuel filter Only work on the fuel supply when the diesel engine Is cold and shut ee eo, >> Shut down roed paver and remove ignition key. >> Open engine/fuel filter maintenance fiap. v The fuel filter [1] is accessible. >> Place suitable container under the fuel filter [1] to collect the escap- Ing fuel. >> Undo fuel fiter cartridge using a strap wrench. >> Dispose of fue! filter cartridge with due care for protecting the envi- ronment. joseph Vogele AG 2016 BAL_1382_2125422 01 en 177 / 253Maintenance Engine / motor group lw] VOGELE >> Wipe up any fuel thet escapes using an absorbent cloth and dispose of taking due care for the protection of the environment. >> Clean sealing surface on the filter carrier. > Slightly oll the seal on the new fuel filter or moisten with diesel, >> Screw on fuel flter cartridge by hand until the seal Is in contact. >> Tighten fuel filter cartridge by % of a turn. >> Check fuel system for leaks. >> Lock engine/fuel filter maintenance flap. The fuel fiter has been changed. 4.04.03 Air intake 4 8 6 Fig. 4-9; Air fiter housing [1] Dust discharge valve [4] Secondary filter [2] Wire fastener [5] Maintenance indicator [3] Main filter, [6] Cover Danger due to hot engine Parts of the engine can be very hot - risk of injury! ‘= Wear personal protective equipment, + As far as possible, do not touch any part of the engine, 478 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE Maintenance Engine / motor group Danger due to rotating parts ‘The V-belts of the altarnator 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 on the road paver. + Donot reach into rotating parts. + Donot wear loose clothing or jewellery. Maintaining the dust dis- >> Maintain dust discharge valve [1] daily. charge valve > open the bonnet. The all fiter Is accessible. >> Remove any baked on dust deposits by pressing the dust discharge valve [1] together. The dust discharge valve [1] must be clear; it ‘must not be in contact with any other object. >> Replace a damaged dust discharge valve [1]. The dust discharge valve [1] must point downward, The dust discharge valve has been mainteined. Maintaining the air filter The condition of the main filter can be read from the maintenance in- dicator [5]. ‘The yellow indicator piston is pressed in: — Main filter Is in proper condition ‘The yellow indication piston is pressed out ("Service" is displayed on ‘red background): — Main filter must be cleaned or replaced >> After cleaning or replacement of the filter, reset the warning indica~ tor by pressing the yellow indicator piston. How the filter's cleaned or replaced, Is described in the next section. The air fiter is maintained. Changing the filter >> Open the bonnet. > Unlock wire fasteners [2] and remove the cover [6]. >> Completely pull main filter [3] off the inner support tube while rotat- ing slighty. >> Carefully wipe out inside of housing with a damp cloth, Do not wash ‘out or brush main fer Never clean filter cartridges with petrol or other liquids. >> Blow out main filter (3] using dry compressed air (max. 72 psi / 5 bar). Blow from the inside outwards. >> Carefully chack main filter [3] for damage to the filter paper (use @ light behind) and to the rubber seals. ~ Do not re-use a damaged main filter [3]- = Replace main filter [3] at the latest once a year, independent of the usage of the machine, ‘As minor damage Is very difficult to see, Vogele recommends to in- stall always a new main filter [3]. Replaco cocondary filter [4] with every fifth time the main filter [3] Is maintained or every two years. >> Take hold of secondary filter [4] at the handle and pull out with slight rotary movements. >> Do not clean secondary filter [4] and do not re-use after removal. >> Push new secondary filter Into the inner support tube, >> Carefully push the open end of main filter [3] onto the housing. >> Fit cover [6]. The dust discharge valve [1] must point downward. >> Fit wire fasteners [2] and fasten. >> Dispose of old filters with due care for the environment. ¥ The filters have been changed. 180/253 BAL_1382_2125422 01 en © Joseph Vegele AG 2016RY VOGELE conn mens Engine / motor group 4.04.04 Cooling system Fig. 4-10: Combined cooler [4]. Coolant flee cop [4] Intercooler [21 Sight glass [5]. Hydrauie ol cooler [3]. Expansion vessel [6] Coolant cooler ea Never run the engine without coolant. Visually check the radiator prier to each work deployment. Danger due to hot coolers The coolers / rediator and parts of the coolers / radiator may be very hot - risk of injury! + If possible do not touch any parts of the coolers. + Observe instruction labels on the road pave + Wear personal protective equipment. Checking the cooling sys- >> Ensure the cooler [4] - [6] is hand warm. tem >> Visually inspect radiator [4] - [6] for damage (leaks, damaged fins, etc.) Visually inspect. > Visually inspect cooler [4] - [6] for soiling and clean with com- reseed air. Do not point a compressed air jet directly at the fins. The cooling system has been checked. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 381 / 253Maintenance earner bts [w] VOGELE 4.04.04.01 Chan Fig. 4-11: Draining the coolant [71 Drain plug Danger due to hot coolant ‘The coolant can be very hot - risk of injury! ‘+ Wear personal protective equipment. + IF possible do not touch any parts of the units. '» Avoid skin contact with coolant, ‘+ In case of injuries, seek immediate medical attention. Draining the coolant >> Shut down road paver and remove ignition key. —__ 99 Open the bonnet. v The coolant filler cap [1] is accessible. >> Open coolant flar cap [3] >> Open left side trim panel. ~The drain plug [7] is accessible. > Have a suitable container at hand, note capacities. >» Undo drain plug [7]. > Fully drain coolant using a channel >> Re-fit drain plug [7] with a new sealing ring and tighten. > Dispose of coolant with due care for protecting the environment. >> Lock lat side trim panel. The coolant has been drained. 182/253 BAL_1382_2125422_01_en © Joseph Vegele AG 2016itenance VOGELE Hydraulic oll feed Observe the cooling system protection concentration givan In the maintenance schedule! Never operate the engine without coolant, not elther for a short time! Filling the coolant >> Add fresh coolant via coolant fille cap [1], use a funnel as an aid. >> Fill expansion vessel [3] at least to the middle of the sight glass [2] with coolant. >> Close coolant filer cap [1]. >> Allow engine to warm up until the thermostat has opened (approx. 95°C), >> Switch off the engine. >> Check coolant level with the engine cooled down and top up if nec- essary. >> Close bonnet. The coolant hes been filed, e ‘The cooling system bleeds itself automatically efter filing. 4.05 Hydraulic oil feed Danger due to hot oil ll and parts of the machine can be very het - risk of injury! + Wear personal protective equipment. + If possible co not touch any parts of the units. + Avoid skin contact with olls and greases. + In case of injuries, seek immediate medical attention. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 183 / 253Maintenance Hydraulle oll feed lw] VOGELE PY Danger due to hydraulic oll escaping under pressure ‘The oll in the hydraulic system is under pressure - risk of injury! + Depressurise hydraulic system. + Lower hopper walls. + Set down screed en the ground. + Switch off all conveyor and compaction systems. ‘+ Shut down engine and remove ignition key. + Attach warning to operator's console. "+ Secure road paver against switching en again or placing in op- eration again. + Wear personal pratective equipment, Observe the following instructions: ‘+ The quality of the hydraulic oll as the lubricant and operating medi- um of every hydraulic system Is crucial to the performance, reliabil- Ity 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 carefully. ‘+ Regularly check the oll level. + Observe oll change intervals. + Always change the oll when It Is at operating temperatura. + Replace filters as specified, + Avold solling of the ell cooler. + Thoroughly clean rozd paver and all connections prior to disman- tling. ‘+ Protect disconnected, open pipes against dirt. + Tighten leaking threaded fittings at operating temperature when de- pressurised. 184/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016(w] VOGELE spurl 4.05.01 Hydraulic tank 4.05.01.01 Changing the hydraulic oil Fig. 4-12; Hydraulic tank Fig. 4-13: Draining the hydraulic of! [1] Hydraulic of filer cap [3] Oil drain hose [2] Fill level indicator [4] Fastening clip (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 385 / 253Maintenance Hyerait fae lw] VOGELE 9 the hydraulic oil A oll drain hose [3] is fit to the hydraulle tank. > The oil must be in at operating temperature. >> Observe special safety instructions at the beginning of this section. >> Open right side trim panel. Danger due to hot il Ol and parts of the machine ean he vary hat - Hel af injury! + Wear personal pratective equipment, + If possible do not touch any parts of the units. + Avoid skin contact with olls and greases. + In case of injuries, seek Immediate medical attention. The hydraulic ol drain hose Is attached next to the oll drain hoses for gearbox oll and engine oil, Do not mix up oll drain hoses, For safety reasons trace back the hoses. >> Loosen fastening clip [4]. >> Have a suitable contsiner at hand, note capacities. >> Open hydraulic tank / sockets maintenance flap. ¥ The hydraulic olf filer cap [1] Is accessible. >> Open hydraulic ol filer cap [4]. >> Guide ul hei ase [3] Inte the container. > Undo sealing plug using a suitable tool. >> Completely drain ol >> Mount and tighten sealing plug. > Lay oll drain hose [3] without kinks and secure with fastening clip (4). > Digpose of waste oll with due care forthe environment. ¥ The hydraulic ol has been drained. Fill with hydraulic oil >> Add fresh oll via hydraulic oil filler cap [1], use a funnel as an aid. >> Top up hydraulic tank to the middle of the level gauge [2] with hy dreulie oll. “The filling level must be visible in the level gauge [2] and should be between 1 and % of the max. level. With the diesel engine shut down, the lovel [2] must not be below the MIN mark. >> Close hydraulic oil filer cap [1]. >> Start road paver and bring to operating temperature. >> Switch off the engine. >> Check level in the level gauge [2] and fill f necessary with oil to % of the max. level. >> Close hydraulic tank / sockets maintenance flap. The hydraulic oll has been filled. 186 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016(w] VOGELE Maintenance Hydraulic oll feed 4.05.01.02 Cleaning the filter screen Fig. 4-142 ‘Fitor screen [1] Hydraulic oi! filler cap [3] Filter screen [2] Sealing flange ‘The filter screen [3] sits in the hydraulic tank and must be cleaned. >> Open hydraulic oll filer cap [1]. >> Loosen fastening screws and remove sealing flange [2]. >> Remove filter screen [3] with lower and upper seal from the file Danger due to airborne particles When blowing cut the filter screen, particles can become airborne {and cause eye injuries. + Wear personal protective equipment. >> Clean filter screen [3] from the outside in (blow out with compressed air). >> Fit filter screen [3] In the reverse order of removal. >> Dispose of waste cil with due care for the environment. The filter screen has been cleaned or replaced. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 187 / 253aces [w] VOGELE Fig. 4-15: Hydroutc tank [4] Runback suction fiter cap [3] Overfiow cil filter connector [2] Runback suction fiter con- [4] Overflow cil filter cap rector In case of solling the pressure in the filters increases. When the capacl- ty of the filters is exhausted, a corresponding error message appears on the operator's console display. Pull off connector [2] or [3] on the related fllter and check whether the ‘error message Is still indicated on the display on the operator's console. {Tf this Is not the case, the related filter must be replaced. Both filters (runback suction filter and overfiow oll filter) must be replaced and the filter screen cleaned when the hydraulic oll changed. 188 / 253 BAL_1382_2125422_01_en © Joseph Vegele AG 2016Maintenance Hydraulic oll feed Replacing the overflow oil filter Replacing the overflow oil filter Fig. 416: Overfow ol itor [5] cap [6] Filter >> Observe special safety Instructions at the beginning of this section. >> Open hydraulic tank / sockets maintenance flap. Danger due to hot oil Cl and parts of the machine can be very het - risk of injury! + Wear personal protective equipment. + If possible co not touch any parts of the units. ‘+ Avoid skin contact with oils and greases. ‘+ In case of injuries, seek immediate medical attention. >> Unscrew cap [5] >> Remove the cap [5] with fier [6]. >> Fit new filter [6]. Check for correct seating ofthe filter. >> Clean and slighty oll the seal of the cap [5]. >> Close cap [5]. >> Tighten the fastening screws. ¥ The overfiow cil filter has been changed. joseph Vogele AG 2016 BAL_1382 212542201 en 189 / 253Maintenance Hydraulle oll feed [w] VOGELE Replacing the runback suction filter Replacing the runback ‘suction filter Fig. 4-17: Runback suction titer [71 Top part [9] Dirt trap [8] Filter >> Observe special safety instructions at the beginning of this section, >> Open hydraulic tank / sockets maintenance flap. Danger due to hot oll and machine parts Oil and parts of the machine can be very hot - risk of injury! + Wear personal protective equipment. ‘+ If possible do not touch any parts of the units, + Avold skin contact with oils and greases. + Incase of injuries, seek immediate medical attention. >> Unscrew cap [5]. The runback suction fiter is accessible. >> Remove the top part [13]. 2> Remove the fiter [8] with the dir trap [3]. >> Fit new filter [8] with cleaned dirt trap [9]. Check for correct seating of the filter. > Fil iter housing with nev oll to the top edge of the fiter [8]. >> Fit top part [7] >> Clean seal and cil lightly. >> Close cap [5]. 190/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE Maintenance Hydraulic oll feed >> Tighten the fastening screws, The runback suction filter hes been replaced. 4.05.01.04 Bleeding the hydraulic oil filter 10 Bleeding the runback suc- tion filter Fig. 4-18: Hydraulic tank [10] Bleed screw of runback suc~ ton filter ‘The runback suction filter must always be bled when changed. >> Observe special safety instructions at the beginning of this section. >> Open hydraulic tank / sockets maintenance flap. ¥ The bleed screw [10] is accessible, >> Start engine, >> Loosen the bleed screw [10], and bleed air if necessary. >> Tighten bleed screw [10] as soon as oll escapes on the bleed screw. >> Wipe up any oll that escapes using an absorbent cloth and dispose of with due care for the environment. The runback suction filter has been bled. joseph Vogele AG 2016 BAL_1382 212542201 en 391 / 253mca lw] VOGELE 4.05.02 Pump distribution gearbox 4.05.02.01 Changing the gearbox oil Fig 419: Oilarain howe Fig. 4-20: Sight glass [4] Oil drain hose [2] Sight glass 192/253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016itenance VOGELE 2 Hydraulic oll feed Check for correct gearbox oil level in the pump distribution gearbox us- Ing the sight glass [2] each time prior to starting work. The level must be visible in the middle of the sight glass [2] An oil drain hose [1] is fitted to the sump. The oll drain hose [1] is routed on the right ofthe road paver in the direction of travel and is fastened to the inside of the front wall. >> The oll must be at operating temperature, otherwise leave road pav- er to run at idle for ten minutes >> Observe special safety instructions at the beginning of this section. >> Open right side trim panel. Danger due to hot oil Cll and parts of the machine can be very hot - risk of injury! + Wear personal protective equipment. + If possible co not touch any parts of the units. + Avoid skin contact with oils and greases, ‘In case of injuries, seek immediate medical attention. The oll drain hose [1] for the gearbox cil is next to the oil drain hose for the engine oil and the hydraulic oil drain hose, Do not mix up oll ‘rain noses. Fer safety reasons trace back the hoses. >> Undo fastening clip. >> Have a suitable container at hand, note capacities. >> Guide cil drain hose [1] into the container. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 193 / 253Maintenance Hydraulic oll Feed lw] VOGELE Adding gearbox oi Fig. 4-21: Filler cap Pump distribution gearbox [3] Gearbox oil fill cap >> Open the bonnet, The gearbox oll fill cap [3] Is accessible, >> Open the gearbox of fil cap [3]. >> Undo sealing plug using 2 sultable tool. >> Completely drain oil, >> Mount ané tighten sealing plug, >> Lay oil drain hose [1] without kinks and secure with fastening clip. >> Dispose of waste oll with due care for the environment. The gearbox oil has been drained. >> Open the bonnet. ¥ The gearbox cil fill cep [3] is accessible, >> Open the gearbox of fil cap [3]. >> Add fresh oll via gearbox oil fil cap [3], use @ funnel as an aid. >> rill sump te the middle of the sight glass [1] with fresh oll. > Close the gearbox ol fill cap [3]. >> Wipe up any oll that escapes using an absorbent cloth and dispose of taking due care for the protaction of the environmant. >> Allow engine to run for approx. two minutes. >> Allow gearbox to warm up. >> Switch off the engine. > Check oil level at the sight glass [1] and top up with oil to the middle of the sight glass [1] if necessary. 194/253 BAL_1382_2125422 01 en © Joseph Vogele AG 20167] VOGELE Maintenance Electrical system >> Check engine / pump distribution gearbox unit for leaks, >> Close bonnet. ¥ The gearbox cil has been filled, 4.06 PTs! Danger due to electric shock Leads and components are live - risk of injury! ‘Some cables and components are stil live, even if the engine Is stationary. + Only perform work on the electrical system when the engine has stopped. ‘+ Walt three minutes after shutting down the engine before start Ing work on the electrical system. Observe the following instructions: + During all maintenance work on the electrical system, obst manual. + Park road paver on firm, level ground. + Shut down engine and remove ignition key. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 195 / 253=. fi] VOGELE 4.06.01 24 V power supply Fig. 422: Starter botery [1] Main fuse / positive cable [4] Starter battery [2] Jumper teeu [5] Sealing plug [3] Earth cable [6] Retaining plate ‘The starter batteries must be kept clean and dry. ‘The acid level in the starter batteries [4] must be checked regularly end ‘the acid topped up If necessary. Danger due to battery acid Battery acid is a caustic liquid. There Is a risk of injuries! "+ Wear personal pretective equipment. "+ Never pour battery acid into bottles for drinks or similar con- tainers. 196 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016iw] VOGELE Maintenance Electrical system ‘Topping up the starter batteries Changing the starter bat- tery PY. Danger when handling batteries Risk of explosion due to the formation of "detonating gas”! ‘+ Wear personal protective equipment. ‘= Wait 2 while after opening the trim panel to allow air to enter. + Donot smoke, no naked flames. + Avoid short circuits and sparks. + Donot place tools on the batteries. Warning of toxic substances ‘The battery mounting, battery terminals end other related eccesso- ries contain lead and lead compounds. + Always wash hands after handling. + Only start and run the engine in well-ventilated places. + If in an enclosed area, vent exhaust to the outside. = Donot modify the exhaust system. >> Open left side trim panel. ¥ The sealing plug [5] is accessible, >> Add distilled water via sealing plug [5], use a funnel as an aid. ‘The acid level must reach the bar inside. >> Close sealing plug [5]. >> Ifthe starter turns slowly, check the specific gravity of the acid in the starter batteries (4]. >> If the specific gravity of acid cells has fallen or ifthe cells are dam- aged, replace starter battery. >> Check cable connections. The starter battery has been topped up. >> Shut down engine and remove ignition key. >> Determine which starter battery Is faulty. >> Remove cover for the main fuses [1] and place on one side. >> Undo leads on the main fuses [1] and pull off. >> Undo leads on the starter batteries [4] in the following order and pull off = Earth cable [3] on the rear starter battery ~ Positive cable [1] on the front starter battery = Jumper [2] between the starter batteries >> Loosen retaining screws using a suitable tool. >> Remove retaining screws and retaining plate [6]. >> Replace starter battery [4], ensure itis fitted in the correct position. Dispose old battery environmentally suitable. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 197 / 253santenance [w] VOGELE >> Clean battery poles and terminals and grease with acid-free, acid- resistant grease, >> Fit cables to the starter batteries [4] in the reverse order of removal. The terminal connections must have good contact, >> Ensure the battery terminals have not been reversed (danger of short eircutt!). >> Fit retaining plate and retaining screws. >> Check starter battery for firm seating. >> Fit cables to the main fuses [1]. >> Fit cover for the main fuses [1]. The starter battery has been changed. Checking the specific >> Open lef side trim panel ravity of acid The sealing plug [5] is accessible. >> Check specific gravity of the acid in the individual cells using a com- mercially available test instrument. — During the measurement, the acid should be at a temperature of 20°C (68°F) if possible. ~ A chart with the specific gravity of acid and charge state Is given in section 4, >> Close sealing plug [5]. The specific gravity of the acid has been checked. 4.06.02 Switch cabinet / power supply / socket Perform the following service work: ‘+ Regularly visually inspect sockets, '+ Check seating of the protective flap and locking clip. 4.06.03 Generator ‘The generator is maintenance-free. 4.07 Not used 198 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE since Advance drive 4.08 Advance drive 4.08.01 Crawler Risk of material damage ‘The rubber of the track bands can be damaged. + Ensure that the rubber of the track bands do not come In con- tact with ol or fuel. + Do not clean track bands with release agents that contain ol, petrol, diesel or kerosene, + Clean track bands with soap and hot water. jing the crawler >> Visually inspect the crawler and track bends regularly. >> Keep the track bands, track rollers, drive and guide wheels clean. >> Remove the asphalt from the track bands, track rollers, drive and uide wheels before it hardens. >> Remove baked on deposites from the rubberized surfaces. The crawler has been maintained. For cleaning the track bands, those have to be released, see section 4,08.01.01. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 199 / 253Maintenance eaieean [w] VOGELE 4.08.01.01 Releasing and ten: ing the track bands Fig. 4-23: Valve block [1] Setscrew [2] Lock nut a ‘The road paver may tip and cause fatal injuries. '* Wear personal protective equipment, «Check whether the bucks are designed for the weight of the as + Read safety manual. eee eee SS Releasing the track bands >> Shut down road paver and remove ignition key. >> Jack up road paver. >> Secure road paver against unintentional rolling away / movernent. DP Ralze hopper wallo and lock. >> Switch off the engine. >> Open right side trim panel. The valve block is accessible. >> Undo lock nut [2] with hexagon socket screw key, but do not un- screw completely, >> Release the setscrew [1] with three turns of an allen key. 200 / 253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016Maintenance VOGELE —Kinancotrve Fis. 4-24; Releasing hand pump of the wack bands [3] Lever [5] Hand pump [4] Ball valve >> Place ball valve [4] In vertical position. >> Insert lever [3] in the receptacle on the hand pump [5]. >> Release track bands by pumps. >> Remove lever [3] and insert in the bracket. > Place ball valve [4] in horizontal position. bands >» Tighten the setscrew [1] and the lock nut [2] on the valve block. The track bands tension automatically when the engine Is started. (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 201 / 253Maintenance eaieean [w] VOGELE 4.08.02 Advance drive Fig. 4-25: Advance drive [41 Filler / oil level plug [2] Ol drain plug ‘The hydrostatic compact drive Is maintenance-free; it Is only necessary to change the gearbox oil. 4.08.02.01 Changing the gearbox Danger due to hot cil Coll and parts of the machine can be very hot - risk of injury! ‘+ Wear personal protective equipment. "+ If possible do not touch any parts of the units, ‘+ Avoid skin contact with oils and greases, ‘+ Incase of injuries, seek immediate medical attention, Risk of material damage ‘The rubber of the track bands can be damaged. '* Ensure that the rubber of the track bands do not come in con- tact with oil or fuel. 202 / 253 BAL_1382_2125422_01_en © Joseph Vegele AG 2016VOGELE Maintenance Steering system Checking the leval_ >> Park road paver on level ground and secure against rolling away. Adding gearbox >> Switch off the engine. ‘The oil level plug [2] must be at the lowest point, >> Unscrew filer cl level plug [1] using a suitable tool. >> The level must be at the bottom edge of the threaded hole, other- wise top up gearbox ol. >> Inset filer / oll drain plug [1] using # new sealing ring and tighten. VThe lavel has hean checked >> Park road paver on level ground and secure against rolling away. >> Switch off the engine. >> Have a suitable container at hand, note capacities. >> Open filler / ol drain plug [1]. >> Loosen oil drain plug [2]. >> Fully drain oil using a channel >> Reeft oll drain plug [2] with @ new sealing ring and tighten. >> Dispose of waste oll with due care for the environment. The gearbox oil has been drained. >> Unscrew filler / oll drain plug [1]. 2? Till new oll viathe filer [1]; use a funnel with extension. >> Add gearbox oil until it escapes at the threaded hole of the filler / oil level plug [1]. >> Insert filler / oll drain plug [1] using 2 new sealing ring and tighten. >> Close filler / ol drain plug [1]. >> Wipe up any oil that escapes using an absorbent cloth and dispose of ‘taking due care for the protection of the environment. The gearbox oil has been filed. 0a Always maintain left and right gearbox. 4.09 Steering system ‘The steering system Is maintenance-free. 4.10 Conveyor unit 4.10.01 Push roller >> Regularly clean push rollers. ‘The bearings of the push rollers are maintenance-free. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 203 / 253cotoortr [w] VOGELE 4.10.02 Material hopper/ entry flap Danger due to hot surfaces Parts of the material hopper are very hot ~ risk of injury! ‘+ Wear personal pretective equipment. + Dornot touch any parts of the machine if possible. ‘When working on the open material hopper; park road paver on firm, level ground. >> Regularly check lugs on the hydraulic rams, clean and lubricate beerings if necessary. 4.10.03 Conveyors 4.10.03.01 Tensioning the conveyor chain Fig. 4-26: Checking the conveyor tension (example wheeled road pavers) [1] Conveyor chain [2] Chassis bottom edge A correctly tensioned conveyor chain must not be under tension on its loose side at any time during movement. >> Regularly check the conveyor chain [1] for correct tension and re- adjust if necessary. ‘To check the tension the road paver must be driven over a pit. 204 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE corel ar i PY. ‘Danger due to heavy load ‘The road paver may tip and cause fatal injuries. + Wear personal protective equipment. © Check whether the pit is designed for the weight of the road paver. © Read safety manual. ‘+ Remove load on screed and mechanically lock. + Observe ground clearance of the screed and the auger blades. ‘+ Read operating instructions on the screed. Checking the conveyor >> Drive road paver over a pit. chain tension >> shut down road paver and remove Ignition key. ‘The convayor chain [1] runs along the bottom of the road paver between two wearing plates. >> Check chain tension on the conveyor chain [3] at the deepest point of the conveyor chain. ‘The optimum chain tension is achieved if the pins of the conveyor chain [1] are at the height of the bottom edge of the chassis [2]. The chain tension has been checked. Making adjusting screws accessible. Fig. 4-27; Hydraulic entry Map (option) [3] Pin [4] Locking clip joseph Vogele AG 2016 BAL_1382 212542201 en 205 / 253conport lw] VOGELE Making adjusting screws >> Ralse hopper walls and lock. Sa Reraeg) 22 Sele nhac ‘Support or holé hydraulic entry flap. >> Pull locking clip [4] from the pin [3]. >> Undo pin 1. >> Fold up complete entry fap. > Lower hopper walls. The adjusting screws are now accessibe, ‘Making adjusting screws >> Fold down hopper walls and entry flap. accessible (mech. entry are now accessible. GRtEy >> The adjusting screws ‘Tensioning the conveyor chain Fig. 428: Conveyors [5] Conveyor chain [7]. Fastening screw [6] Adjusting screw [8] Locking plate ‘Tensioning the conveyor >> Clean area around the adjusting screws [6]. chain >> Loosen fastening screws [7] of the locking plates [8]. >> Remove the locking plate [8] for the adjusting screws [6]. >> Turn adjusting screws [6] until the correct chain tension Is achieved. - Tum adjusting screw clockwise: Reduce conveyor chain tension. = Tum adjusting screw counter-clackwise: Conveyor chain is ten= sloned. 206 / 253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE cotef er “The optimum chain tension is achieved if the pins of the conveyor chain [5] are at the height of the bottom edge of the chassis [2], measured at the lowest point of the conveyor chain. >> Tension chain evenly at both adjusting screws [6]. >> Check chain tension. >> If necessary, tension conveyor chain again. >> Fit locking plate [8] for the adjusting screws [6]. >> Tighten fastening screws [7] on the locking plates [8]. >> Fit entry flap n the reverse order of removal and close, The conveyor chain has been tensioned. e Always maintain both conveyors. 4,10.03.02 Tensioning the drive chain ia. 4-29: Conveyor drive [4] Mounting [4] Adjusting screw [2] Measuring range [5] Fastening screws [3], Lock nut Regularly check the drive chain for correct tension and lubrication, re~ adjust and lubricete if necessary. joseph Vogele AG 2016 BAL_1382 212542201 en 207 / 253Maintenance Conveyor unit lw] VOGELE ‘Tensioning the drive chain ‘The drive chain is tensioned by adjusting the mountings. >> Check chain tension at the measuring range [2]. Jt must not be possitle to press the drive chain in more than ¥2 inch / 32 mm by hand. >> Loosen the four fastening screus [5] of the drive unit, however, do not unserew them completely. >> Undo lock nut [3] on the adjusting screw [4]. >> Turn adjusting screw [4] until correct chain tension is achieved. ~ Tum adjusting screw clockwise: Drive chain tension is reduced, — Tum adjusting screw counter-clockwise: Drive chain is tensioned. >> Check chain tension at the measuring range [2]. >> If necessary, tension drive chain again. >> When the chain tension is correct, tighten lock nut [3]. > Tighten fastening screws [5] on the drive unit. The drive chain has been tensioned. 4.10.03.03 Changing the gearbox oil Fig. 4-30: Conveyor drive unit [1] Oil level plug [3] Filler neck / ventilation [2] Oil drain plug ‘The gearbox of the drive unit Is maintenance-free; It Is only necessary to change the gearbox oil regularly, 208 / 253 BAL_1382_2125422 01 en Joseph Vogele AG 2016iw] VOGELE conveyer int (CAUTION Danger due to hot oil Oil and parts of the machine can be very hot - risk of Injury! ‘Wear personal protective equipment. + If possible co not touch any parts of the units, + Avoid skin contact with olls and greases. ‘= In case of injuries, seek immediate medical attention. Risk of material damage “The rubber of the track bands can be damaged. + Ensure that the rubber of the track bands do not come in con= tact with oil or fuel. Drai >> Park road paver on level ground and secure against rolling away. >> suiteh off the engine. >> Open the side trim panel. >> Have a suitable container at hand, note capacities. > Open the filler neck / ventilation [3]. >> Loosen oil drain plug [2]. >> Fully drain oll using a channel, >> Ke-ft ol! drain plug [2] with 2 new ocaling ring and tighten. >> Dispose of waste oll with due care for the environment. The gearbox all has baen drained. Adding gearbox oil >> Loosen oil level screw [1]. >> Fill new oil via the filler neck / ventilation [3]; use @ funnel with extension, >> Add gearbox oll until the gearbox oll escapes at the threaded hole for the oil level plug [1]. >> Close the filler neck / ventilation [3]. >> Re-fit oll level plug [1] with 2 new sealing ring and tighten, >> Wipe up any cil that escapes using an absorbent cloth and dispose of taking due care for the protection of the environment, The gearhay all has been filed. ea Always maintain left and right drive unit. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 209 / 253Maintenance cation [w] VOGELE 4.10.03.04 Cleaning the conveyors Warning of crushi Conveyors and distribution augers run at moderate speed in the cleaning mode and can cause fatal injuries and death. ‘+ Observe instruction labels on the road paver. ‘+ Do not reach into rotating parts. + Do not wear loose uth ur Jewettary. “+ Ensure the sefety devices are fully ited. When working on the open material hopper, park road paver on firm, level ground. >> Regularly clean conveyors. 4.10.04 Distribution augers Fig. 4-31: Distribution augers drive unit [11 Cover plate [3] Gearbox [2] Gearbox with drive moter [4] Mounting 210/253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE Maintenance Conveyor unit Danger due to hot grease Escaping grease Is hot - risk of injury! "+ Wear personal protective equipment. + Avoid skin contact with olls and greases. + In case of injuries, seek immediate medical attention. Lubrication check >> Remove cover plate [1] at the gearbox [2]. The drive chain Is now accessible. >> Check the lubrication in the gearbox, ‘You must see grease adhering to the sprockets and drive chains. >> If there is not enough grease, check lubrication unit and ~ Menual lubrication of central lubrication point or — Fill reservoir of the central lubricating system (option) with ‘grease, see section 4.18. >> Fit cover plate [1] and bolt in place. Lubrication has been checked. 4.10.04.01 Ten: ing the dri Fig. 4-32; Distrvution augers drive unit [5] Adjusting serew [7] Fastening screw [6] Leck nut ‘Tensioning the drive The drive chain is tensioned by adjusting the mountings [4]. chain >> Remove cover plate [1] at the gearbox [2]. joseph Vogele AG 2016 BAL_1382 212542201 en 214/253Maintenance Conveyor unit lw] VOGELE The drive chain is accessible, >> Check chain tension in the measuring area under the cover plate [1]. It must not be possible to press the drive chain in more than 0.24 Inch / 5 - 6 mm by hand. >> Loosen the four fastening screws [7] on the mountings [4], but do not remove them. >> Undo lock nut [6] on the adjusting screw [5]. >> Turn adjusting screw [5] until the correct chain tension Is achieved. — Tum adjusting screw clockwise: Drive chain Is tensone ~ Turn adjusting screw counter-clockwise: Drive chain tension Is reduced, >> Check chain tension at the measuring range behind the cover plate (ah >> If necessary, tension drive chain again, >> When the chain tension Is correct, tighten lock nut [6]. >> Tighten fastening screws [7] on the mountings [4]. >> Fit cover plate [1] and bolt in place. The drive chain has been tensioned. e ‘Always maintain lft and right drive chain, 212/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE crore 4.10.04.02 Changing the gearbox oil Fig. 4-33: Distribution augers drive unit [1] Gearbox oll filler [3] Oil drain plug [2] ll level plug ‘The gearbox of the drive unit is maintenance-free; it is only necessary to change the gearbox oil regularly. Danger due to hot oil (oll and parts of the machine can be very hot - risk of injury! ‘+ Wear personal protective equipment. + If possible ¢o not touch any parts of the units, ‘+ Avoid skin contact with oils and greases. = In case of injuries, seek immediate medical attention. .arbox oil >> Park road paver on level ground and secure against rolling away. >> Switch off the engine. >> Have a suitable container at hend, note capacities. >> Open the gearbox oil filer [1]. >> Loosen oil drain plug [3]. >> Fully drain oll using a channel, >> Re-fit oll drain plug [3] with a new sealing ring and tighten. >> Fit plug to the gearbox oil filler [1] and tighten. >> Dispose of waste oll with due care for the environment. The gearbox cil has been drained. Draining the joseph Vogele AG 2016 BAL_1382 212542201 en 213/253Maintenance Levelling unit lw] VOGELE Adding gearbox 4.10.04.03 Cleaning the distribu 4.11 e >> Loosen oil level screw [2], > Fill new oll via the gearbox oil filer [1]; use a funnel with exten= sion. >> Add gearbox oil until the gearbox oll escapes at the threaded hole for the oll level plug [2]. >> Close the gearbox oil filler [1]. >> Re-fit oll level plug [2] with @ new sealing ring and tighten. >> Wipe up any oll that escapes using an absorbent cloth and dispose of taking due care for the protection of the environment. The gearbox all has been filed. ‘Always maintain left and right drive unit. n augers Warning of crushing hazard Conveyors and distribution augers run at moderate speed in the Cleaning mode and can cause fatal injuries and death. + Observe instruction labels on the road paver. + Do not reach into rotating parts. + Donot wear loose clothing or jewellery. "+ Ensure the safety devices are fully fitted, When working on the epen material hopper, park road paver on firm, level ground. > Regularly clean distribution augers. Levelling unit @e “The NIVELTRONIC Plus® was designed for high operationel safety. Perform the following service work: ‘+ Regularly checked coiled cables for damage or dirt. ‘+ Keep the threads on the connectors and cable connections free of dirt, grease, asphalt or concrete to avoid bad contacts. + Only use suitable agents. ‘+ Clean loop or ski sensor after use. + Keep height sensor clean. ‘+ Check height sensor housing for damage. 214/253 BAL_1382_2125422 01 en Joseph Vogele AG 2016Maintenance VOGELE Wot used 4.12 Not used 4.13 Cleaner unit 4.13.01 Cleaning filter screen, in the release agent tank (option) Fig. 434; ‘Filter screen [1] Release agent filler cap [3] Filter screen [2] Sealing flange ‘The filter sorcen [31 is in the release agent tank (optional) and must be cleaned. >> Open release agent filler cap []. >> Loosen fastening screws and remove sealing flange [2]. >> Remove filter screen [3] with lower and upper seal from the filler. Danger due to airborne particles ‘When blowing cut the filter screen, particles can become airborne {and cause eye injuries. ‘Wear personal protective equipment, >> Clean filter screen [3] from the outside in (blow out with compressed air). >? Mit ter screen [3] in the reverse order of removal. >> Dispose of waste oll with due care for the environment. > Unscrew cover. tridge >> Place a suitable container under the filter cartridge [2]. >> Undo fiter cartridge [2] using a strap wrench, unscrew and dis~ pose of with due care for protecting the environment. >> Spilled fluid has to be cleaned with an absorbent cloth and disposed of with due care for protecting the environment. >> Clean sealing surface on the filter carrier [1]. >> Slightly ell seal on the new filter cartridge [2]. >> Screw on fier cartridge [2] by hand until the >> Tighten filter cartridge [2] a further half turn, >> Place cleaner unit in operation and check sealing surfaces for leaks. >> Unscrew cover. > Regularly check lugs on the tow point rams [1], clean and lubricate bearings if necessary. © Joseph Végele AG 2016 BAL_1382 212542201 en 217/253Maintenance ee [w] VOGELE 4.14.02 Screed lifting ram Fig. 4-37. Screed iting ram [11 Nipple >> Fit grease gun to nipple [1] and lubricate. >> Check spherical plain bearing on top and lubricate it if necessary. 4.15 Not used 4.16 Not used 4.17 Not used 218 / 253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE Maintenance Lubrication unit 4.18 Lubrication unit 4.18.01 Central lubrication point Manual lubrication of cen- tral lubrication point Fig. 4-38: Central lubrication point [1] Grease nipple, central lubri- ‘cation point >> Open left side trim panel. The central lubricating point Is accessible. >> Fit grease gun to the graase nipple of the central lubricating point ca. Grease escapes at the bearings. >> Remove grease gun from the grease nipple. >> Lock left side trim panel. The central lubricating point has been lubricated. ea Ensure that no alr Is trapped when filing the lubrication unit. joseph Vogele AG 2016 BAL_1382 212542201 en 219/253Maintenance Screed [w] VOGELE 4.18.02 _ Central lubricating system (option) Filling the central lubri cating system a 4.19 Screed Fig. 4-39: Central lubricating systom (option) [4] Reservoir [3] Grease nipple, container fil- ing [2] Greese nipple, emergency [4] Cap. lubrication >> Open left side trim panel. The central lubricating system Is accessible, >> Remove cap [4]. >> Fill reservoir [1] with grease, Keep free of soiling, There must not be any objects in the grease. >> Close cap [4]. >> Lock left side trim panel. The central lubricating system has been filed. Ensure that no air is trapped when filling the lubrication unit. ‘See screed operating instructions. 220 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE Charts ‘Technical data 5 CHARTS 5.00 Technical data 5.00.01 Weights 5.00.02 Operation In this sub-section you will find listed all the technical data relevant for the operation of the road paver. ‘The complete technical data on the road paver are described in sepa- rate documentation from Vagele. ‘The complete technical data on the supplier components are described In the related documentation by the manufacturers, Se Ee Ccorison €2 11 33,708.64 lbs 34,720.56 Ibs 15290 kg 15749 kg Carlson ez 1V 34,755.83 lbs 35,767.75 lbs 15765 kg 16224 kg Tab. 5-1: Opereting weights ofthe road paver ‘This information is important when transporting and loading the road paver. a ee Road paver, general Max. permissible side slope, : 14 right and left ‘Max. permissible uphill Incline ° 10 ‘Max, permissible theoretical ° 45 downhill incline Tab. 5-2: Road paver operation ‘Max. ramp incline to be driven up Front ramp angle ° 14 Rear ramp angle p 14 Ground clearance In 7.08 mm 180 Tab. 5-3: Driving on a ramp. (© Joseph Végele AG 2016 BAL_1382 212542201 en 221/253Tecra ata wi] VOGELE SL Max. paving speed ‘Automatic ymin 249.3266 m/min 7642 Manual backup ‘f/min 103.7 £13 m/min 5644 ECO automatic Amin 203 £6.68 m/min os42 Manual ECO backup A/min 164413 m/min so+4 Max. positioning speed - forwards / reverse ‘Automatic ymin 249 46.6 m/min 7642 Manual backup fe/min 183.7 £13 m/min 5624 ECO automatic fumin 249 46.6 m/min 762 Manual ECO backup ‘f/min 183.7 +13 m/min S644 Max. speed menoauvring / road travel forward Automatic mph 75406 km/h wat Manual backup mph 37 £06 km/h eat Max. speed manoeuvring / road travel reverse ‘Automatic mph 2.8 £06 key 45e1 Manual backup mph 2.8 £0.6 km/h 4541 ap. 9-42 K08d speed ofthe road paver 222/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016Charts VOGELE Technical data 5.00.03 Length of tractor taf 4262 mm ‘Transport width afin 2525 mm Width (hopper open) 10f10in 3300 mm Height (top edge of exhaust to f6in 3190 mm pipe) Minimum height (without pipe) 8h9in 2678 mm Tab. 5-5: Dimensions of the road paver Length with screeds (Carlson EZ 10, 18 f2in 5538. mm Carlson £2 1V 18 ft2in 5538 mm Tab. 5-6: Lengths with screeds Working widths Heating | Full throt- Idle power / | tle oper: a generator | __ tion CarlsonEZIN Standard 9 fe it 19 58m 5.8m 5.8m. CarlsonEZIV Standard 19 fe it 19 58m 5.8m 5.8m Tab. 5-7: Working width of the road paver ‘This information is Important when transporting and loading the road paver. ‘The paving width is reduced if the heated edge formers or balloon lights are fitted. joseph Vogele AG 2016 BAL_1382 212542201 en 223/253Tectia! deta lw] VOGELE 5.00.03.01 Dimension sheet 190mm / 125i Fig. 5-1: Road paver dimension sheet (1) 1943 men /716in| 2525 mm/#109 0 Fig. 5-2: Road paver dimension sheet (II) L* = Dependent on the screed, see working widths 224/253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE Charts ‘Technical data 5.00.04 Adjusting the compaction systems eC Paving speed 16 - 60 fe/min 16-60 f/min 16 - 60 ft/min sell Zane | aoa | aaa aie a ae cg @ ema i= | as | en Ss 2 ee eS Ce SENG te > 121.1°C Tab. 5-8: Adjusting the compaction systems ‘The indicated settings of the compaction systems are recommenda- tions. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 225/253charts Technical data lw] VOGELE 5.00.05 Engine / motor group a ee Engine manufacturer - ‘Cummins Engine type - 9886.7 ¢-170 Number of cylinders pe ‘ Capacity cu in (in3) 409 emo 700 Rated speed rpm/Jmin-i 2000 Low idle rpm / min-1 1045, ECO rated speed pm / mini 1800 Rated power 1 at rated speed hp @ KW 1170/2000 kW at rpm 127/2000 Rated power 2 at ECO speed hp @ kw 1160/1800 kW at rpm 119/1800 Max. torque Ib@rpm 484/240 Nm at rpm 656/1400 ‘Spec. fuel consumption Fuel con- Ib/hp-hr 0.367 ‘sumption (at rated power) g/kwh 229 oF 122 °c 50 Min. permissible ambient temp F -40 ture re =a Engine oil capacity gal 4.50 1 7 Total cooling system capacity gal 7.40 \ 28 Diesel capacity cal 70 1 265 ‘Antifreeze capacity al 3.70 1 4 Water capacity eal 3.70 1 14 Display indication at low idle speed pm 1045 #25 Display indication at ECO speed rpm 1870 +20 Display indication at high idle speed rpm 2060 + 40 Complies with emission standard Ter 3 Tab. 5-9: Diesel engine ofthe road paver 226 / 253 BAL 1382 2125422 01. en © Joseph Vogele AG 2016VOGELE rene ta 5.00.06 Hydraulic oil feed Hydraulic tank capacity gal 42.27 1 160 Total hydraulic system capacity gal 66.0 1 20 Pump distribution year bus ta vat 1.60 pacity 1 3 Conveyor drive capacity gal 034 1 13 Distribution auger drive capacity, sal 0.34 1 13 ‘Suction-retum fter ~ pressure psi 25.72 i) bar 18 (Overflow oll fiter - pressure psi 21.44 oe bar 1s Tab. 5-10: Road paver hydraulic system (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 227 / 253Sonn [w] VOGELE 5.00.07 Electrical system a a Onboard electrical system volt v 24 age Battery type an 2x 110 Halogen working light ww 24/70 (per headlight) Xenon working light (per light) vw 24/42 Flashing light, screed on / off vw 24/15 Beacon ww 24/70 Balloon light vw 230/200 Generator type v 230/400 Tab. 5-11: Road paver eloctrical system Cees Fully charged 1.20 a2 half charged, recharge 142 1.08 discharged, re-charge immedi- ately sah 512° Spe yo a nd Cz ste te te 5.00.08 Advance drive a Hydrostatic compact crive Brake: epring-actuated multiple dise brake, hydraulically actusted Advance drive capacity gal 1.27 1 48 Pressure of parking brake pal 726.75 bar 50 Tab. 5-13: Road paver advance drive 228 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016my Charts VOGELE Technical data 5.00.09 Conveyor unit / distribution So Hopper capacity fe sett m 457 Push roller diameter in 51 mam 340 Push roller, adjusteble to front i 2/4 mm 50 / 100 ‘Number of conveyors pe Bi ‘Number of distribution augers pe 2 Distribution euger chain tension in 0.20-0.24 mm 5-6 Distribution auger diameter i 15.75 mm 400 Distribution auger height adjustment n sat mm 150 Tab. 5-14: Road paver conveyor unit 5.00.10 Levelling unit SS ee ‘Max. paving thickness in 11.81 mm 300 5.00.11 Central lubricating system (option) a pa aC aa : z Tab. 5-16: Central lubricating system © Joseph Végele AG 2016 BAL_1382 212542201 en 229/253Charts Maintenance schedule lw] VOGELE 5.01 Maintenance schedule foreurad Material, spare | Ev Every | Every oo ro 500 h| 1000 fi 5 ‘Operators console clean, as neces- Cleaning agents sary 2050174 ‘stops lean Release agent x Hopper walle clean Release agent x Conveyor lean Release agent x Distribution augers clean Release agent x Push rollers clean Release agent Ey All chain / track ten- check. sions Ventilation system clean x 3.01.01 Engine oil change Engine olf); ap. XX 3.040 4.5 gal / 47 tres Engine oi level ‘check /top up Engine oil” % 3.04.01 Engine oll iter change se spare parts x XK 304.01 catalogue Engine mounting check x Fuel tank cheek Diesel" x x Fuel fiter change see spare parts xX xk 3.08.02 catalogue Fuel pre-fiter Visually inspect x 3.08.02 ‘change ‘20 spare parts xX x 3.0402 catalogue Airfiter main fiter clean renew see spare parts XX 308.08 catalogue Airfter ofthe sec- change see spare parts x ‘ondary filter catalogue Engine coolant check /top up Water, 3.7 gal/14. x 3.08.05 litre; antifreeze" 3.7 gal /14iitre Hydraulic ofl oo Hydraulic ol? or x 3.05.01 bio-hydraulic oll; 6 gal / 250 litre check x Runback suction fiter, change se spare parts x 3.05.01 hydraulics catalogue Overflow oll fter, change. see spare parts x 3.05.01 hhydraulles catalogue 230 / 253 BAL 1382 2125422 01. en Joseph Vagele AG 2016VOGELE Charts Maintenance schedule rere Maintenance | Material, spare | Ev ry work panes rod Cr Ey a Hydraulic tank / re- X 3.05.01 lease agent tank filer fiker Pump distrbution change Special gearbox x X 3.05.02 ‘gearbox ol of; 1.60 gal / S Itres Track bands cleen x 4.08.01 Left / ight advance change Special gearbox x x 3.08.02 drive gearbox oil oi); 1.27 gal / 4.8 lives ‘conveyor chain check / tension x x 30.03 ail Conveyor drive chains chack/ oll ‘Special grease 2") x x x 3.10.03 Left / right conveyor change ‘Special gearbox X 3.10.03 ‘gearbox ol oi! 0:34 gal / 4.3 res check x Distribution auger check / tension x x X 3.10.04 drive chains Distribution auger change Special gearbox x 3.40.04 gearbox oil of); 0.34 gal / 3.3 Ives check x ‘Central lubrication lubricate Special grease 1" x 348 point / Cental uP top up / visual ‘ating system (0P- inspection tion) Hydraulic ram lugs lubricate Special grease 1") x x Tab. 5-17: Maintenance schedule » See lubricant chart In these instructions only appropriately trained service personnel ‘The abbreviation "h” stands for operating hours. ‘The maintenance intervals for the road paver are stipulated by Vogel bbesides the instructions described here, adhere also to the maintenance Instructions of the engine manufacturer. In section 5.04.02 you can find an overview of the suppliers’ documentation. Use only original Vagele spare parts or lubricants, or those that have been approved by Vgele, ‘Observe lubricant chart in section 5.03 of this Operation manual. © Joseph Végele AG 2016 BAL_1382_2125422 01 en 231/253Charts Tightening torques w] 5.02 Tightening torques VOGELE ‘The tightening torques for screws and nuts are glven in tables inthis ‘sub-section. @ ‘Check screws and nuts for tightness at @ regular basis and re- tighten if necessary. ‘You will nd the special tightening torques for fastening the convey- or and compaction systems and their components in the spare parts catalogue at the related item. surfaces and nuts with coarse-pitch threads (coefficient of friction e “The tightening torques inthe charts apply for screws with mating total ed otherwise. 0,42, zinc plated and yellow chromated screws), If not stat- Pee nec class 100 Ms Me Me mio mz mia mis 20 eat 1401 30.98 62.69 95.88 159.64 243.39 492.54 Tab. 5-18: Tightening torques for Verbus Ripo® it 1s a2 85 130 230 330 600 232/253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016Charts VOGELE Tightening toraues eres a a ee ee Se Es EE ee aa Ee a BS ee Sn en ee a ed ed ee Ee a ES EE Ey ES Se SN EE pea as | ces [ee [oem Pe = pas pep) aaa [oo [anes Poe Te) san | eb [ae [a [neem ee Tab. 5-19: Tiyluening torques for coarse-pitch thread © Joseph Végele AG 2016 BAL_1382 212542201 en 233/253Laven tle lw] VOGELE aay ae A es a Ee maxi 17.70 24 «26.55 3630.98 42 Mtoxt 3688 50 5384 7363.43.88 Miod25 3467 47 5089 6959.74 Mi2xi.25 61.96 8492.20 125 «106.95 145 mi2xt 5974 81 88.51 120 103.26 140 Midxi.S 99.57 135 143.82 195 169.64 230 Misxi.5 151.20 205 22127 300 258.15 350 MiBiS 224.96 305 320.84 435 «376.16 510 M2ox15 317.15 430 449.91 610 523.67 710 M2axi.5 427.79 580 612.18 830 708.06 960 Mo4x2 531.04 720 74.44 (1,050 85.07 1,200 M272 774.44 1,050 1,106.34 1,500 1,290.73 1,750 M30x2 «1,069.46 1,450 1,548.88 2,100 1,807.02 2,450 Maxi 1770 24 265536309842 Tab. 5-20: Tiyinening wrques for fine-pitch treed 5.03 Lubricant table ‘The lubricant chart serves as a first orientation for servicing VOGELE ‘machines. It, however, does not replace the recommendations given by 2 lubricant specialist or the manufacturers of engines and gearboxes. To protect the environment, it is absolutely necessary that used oll is, disposed of in due order after servicing or oil change. Lubricants for special applications are not included in this chart. ‘We only grant warranty for our machines when the listed lubri: cants are used, or lubricants which can be proved to be equiva- Tent! ‘*¥ HVBI chert docignations from the Association of the German Con- struction Industry refer to the “usual lubricants" used for construction machinery and vehicles. 234/253 BAL_1382_2125422 01 en Joseph Vogele AG 2016Charts VOGELE ubdeat able Lubricant chart Lubricant | WIRTGEN GROUP cy ps 0 1080 ‘WIRTGEN GROUP Engine of 10W-40, ‘Standard gearbox oil SAE 99 60.80 oa ‘wiRTGeN GROUP Used for: Standard gear~ API-GLS Gear 01 85-40 box (ttypoid goarbox ll) ML L 2105 8 with EP adetives SAE 90 W-90 WLGLS MIL-L-2105 7D, with EP additives ‘Special gearbox oil SAE75 W.90. rs: \WIRTGEN GROUP sed for: Gearboxes with API-GLA/GLS Gear Oil 750.90 high thermal demands Mil-.-2105 & MI-1 with EP adatves Hydraulic oi Hydraulic oll HLP Hyd 0590 He \WIRTGEN GROUP Used for: DIN 51524-2 Hydrauke Of HVLP 46 AT -10°Cto +40°C with EP adltives 1S0-V6 46, Bio-bydraulic oi Bio-hydraute ot BIO. H¥D Used for: VDMA 24568 HEES type 0530 AT-10°Cto +40%C (saturated synthetic ester) PANOLIN HLP Synth 46 ‘Standard lubricating KPF2K-20 Mpc-D st \WIRTGEN GROUP ‘oreases With € adatives Multpurpose Grease NLGI cass 2 ‘Special ibricating KP2R20, siicone-fee MPG-C 2 \WIRTGEN GROUP ‘greases with EP adctives Friction 8 Roller Beor- Used for: ing Grease high thermal demands (central tbvicating sys- tems) ‘Adhering ubsicants wea sa Used for: Open chain transmissions, gearwhoes, stool cables Getrcbefifett GPOON-20 MPG-F = Silicone oreaze for tole NRS 35 \WIRTGEN GROUP scopic tubes of extending Tolescop. Tube Grease screeds Diesel fuel DIN EN 590 == ‘Cooling system pro- Cooling systom protection = tection DeuTZ TR 0199-99-1115 Tab. 5-21: lubricant chart (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 235/253Charts Seperate documentation lw] VOGELE 5.04 Separate documentation ‘Along with these instructions, there are further documents and infor- mation material on the road paver. 5.04.01 Documentation on the road paver Eos | oEn=s [So logue Tab. 5-22: Documents of Vegele ee German 2086367 English 2086365 French 2093474 Spanish 2093476 Tab. 5-23: Safety manual of Vgele 5.04.02 Information material Le cl NIVELTRONIC Plus® Concise instruc~ tions Big Ski ‘Concise instruc 2081625 tions Tab. 5-24: Information material of Vogele ‘These documents can be obtained from végele. 236 / 253 BAL_1382_2125422_01_en Joseph Vogele AG 2016Charts VOGELE Fuse assignments 5.05 Fuse assignments Ss Fi 808 Switch cabinet fuse rating F2 300 Starter fuse rating Fa 225A Preheating system fuse rating Fa 3A Spare Fs 258 Engine management system ECM Fs 758 Tanition 7 458 Controller 2 power Fs 758 Logie supply C1-C3, Limp Home Fo 3A br Fi0 758 Horn, beacon, tank sensor Fa 758 Left outer control stand FR 758 Right outer contol stand F143 758 Power supply CAN node, converter Fis 758 Sensor system FAS 458 24 V socket Fi6 458 Loft working lots Fa 458 Right working lights Fis 758 Storter Fis asa leer unt F20 758 Heating voltage regulator Fa 758 External NIVELTRONIC Plus®, slope sensor F22 758 Power supply CAN nodes 1 F23 758 Power supply CAN nodes 2 Fs 758 Power supply CAN nodes 3 F25 458 Power supply controller 2 F26 458 Power supply controller 3 F27 a58 Power supply controller 3 £28 158 Power supply CAN nodes 30 F29 158 Power supply CAN nodes screed 30 758 options Fat 758 ‘options raz 75h Options F533 758 ‘options 34 758 Tanition for enaine manaament Tab. 5-25: Fuse assignments (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 237 / 253Senses [w] VOGELE 238 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016Assembly and conversion VOGELE Fting and sting up the NNVELTRONC Pus (opr) 6 ASSEMBLY AND CONVERSION 6.00 Fitting and setting up the NIVELTRONIC Plus® (option) Fig. 6-1; NIVELTRONIC Plus® leveling unit [4] Outer control stand [3] Sensors (here long range ultrasonic sensor) [2] Bracket for sensors Fitting the NIVELTRONIC >> Fit outer control stand [1] to the outer control stand bracket on Plus® the end plate and connect. >> Fit bracket for sensors [2] to the screed end plats. v NIVELTRONIC Plus® is ready for use. © Joseph Végele AG 2016 BAL_1382 212542201 en 239 / 253Feng ond setting up the NIVELTRONEC Ph (opton) iw] VOGELE 6.00.01 Fitting and adjusting the mechanical sensors 1 2 3 Fig. 62; Mechanical long range sensor [1] Mounting pipe [3] Ski sensor (14 inch / 0.35 m) [2] Height sensor Fitting the height sensor >> Insert mounting pipe [1] In the sensor bracket and clamp. ~~ >> Insert height sensor [2] in the mounting pipe [1] and clamp. The height sensor has been fitted. Fitting the ski / loop sen- >> Screw loop or ski sensor [3] to the shaft for the height sensor [2]. 50r Loop or ski sensor [3] must be fitted to the height sensor on ‘the left In the direction of travel, independent of whether the height sensor Is fitted on the left or right side of the road paver. = The pin for the height sensor (2] must be positioned on the middle groove on the sensing arm, >> Connect height sensor [2] to the outer control stand (tow point sen= ‘sor connection [2]) using colled cable. The loop or ski sensor has been fitted. Use small ski sensor (14 Inch / 0.35 m) on tight bend radi. Use large ski sensor (38.5 m and 79 Inch / 1.0 und 2.0 m) for large bend radil or on the straight. 240 / 253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016Amat att ae 6.00.02 _ Fitting and setting up the ultrasonic wide range sensor 2 wy ig. 6-3: Fitting the ultrasonic wide range sensor [1] Mounting pipe [2] Ultrasonic wide range sen- sor Fitting the ultrasonic wide >> Insert mounting pipe [1] in the sensor bracket and clamp. range sensor in stringline >> Insert ultrasonic wide range sensor [2] in the mounting pipe [1] mode, “and clamp. ~ Fit centrally and perpendicular to the wire. ~ Set lateral distance to the screed end plate to the same as the distance to the reference lin ~ Fit ultrasonic wide range sensor horizontally. >> Connect ultrasonic long range sensor [2] to the outer control stand (tow point sensor connection [2]) using colled cable. The ultrasonic wide range sensor has been fitted in stringline mode. Fitting the ultrasonic wide >> Insert mounting pipe [1] In the sensor bracket and clamp. range eensor in ground >> tse)t ullrasunie wide range sensor [2] In the mounting pipe [1 mode” Mem la na cl 9 pipe [1] ~ Position ultrasonic wide range sensor in direction of travel. >> Connect ultrasonic long range sensor [2] to the outer control stand (tow point sensor connection [2]) using coiled cable. ‘The ultrasonic wide range sensor has been fitted in ground mode, (© Joseph Végele AG 2016 BAL_1382_2125422 01 en 241/253‘Assembly and conversion Fiting and setting un the NIVELTRONIC Plus®) (open) lw] VOGELE 6.00.03 Fitting and setting up Big Ski Fig. 64: Fitng Big i [1] Mounting arm [4] Ultrasonic wide range sensor [2] wrackete [5] Mounting rail [3] Control electronics >> Fit the brackets [2] for the mounting rail. >> Fit mounting arm [1). - For large working width to the end plate, = For small working width or for scanning within the paving width to the arm. >> Fit mounting rail [5], >> Fit the ultrasonic wide range sensor [4] to the mounting rail. > Connect the ultrasonic wide range sensor [4] with colled cable to the control electronics [3]. >> Connect Control electronics [3] to the outer control stand (tow point sensor connection [2]) using colled cable. / The Big Sid hes been mounted, 242 / 253 BAL_1382_2125422 01 en Joseph Vogele AG 2016Assembly and conversion Fitting and setting up the NIVELTRONIC Plus® (option) Fig. 6-5: Big St control eloctronies ,, Sensor message [10] Calibrate sensor [7] Sensor assignment (LED) [11] Call paremeters [8] Scanning mode (LED) [12] Change parameters [9] Select scanning mode Setting up Big ski The sensor connectors used are indicated by the sensor assignment [7] and on the display [6]. >> Open parameters [11]. ‘Admissible operating window of the sensors is indicated on the dis play [6]. >> Change operating window [421 if necessary. >> Sensor calibration [10]. >> Select scanning mode [3], (see table below). The corresponding LEDs [7] and [8] illuminate. ~The Big Ski has been set up. meen! El ‘Only the middle sensor is used i] a A eee] for scanning | ‘String line scanning using the Eee Bia Ground scanning using the mid- 1 a 2 eee] dle sensor Tab. 6-1: LED indicator of scanning mode © Joseph Végele AG 2016 BAL_1382 212542201 en 243 / 253‘Assembly and conversion Pee a Seg Leo VELIRORNERND Geto [w] VOGELE 6.00.04 Mounting and connecting the ultrasonic sensor Fig. 6-6: Ultrasonic sensor [1] Mounting pipe [4] Reference bail [2] snap agaprer [5] Screw [3] Single sensor ‘The single sensor should be mounted at a height of approx. 17.7 inch / 450 mm to ensure the maximal working range of + 4 inch / 100 mm. Mounting and connecting >> Insert snap adepter (21 in the mounting pipe [2] and clemp. the ultrasonic sensor >> push snap adapter [2] upward and insert sensor [3]. >> Connect sensor [3] to the outer control stand (tow point sensor connection [2]) using coiled cable. ‘> Fasten reference bail [4] to the sensor [3] by means of the screw (s}. The ultrasonic sensor hes been fitted and connected. 244 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 2016VOGELE Assembly and conversion Adjusting the tow point arms 6.01 Adjusting the tow point arms a Adjusting the tow point arms and offsetting to the rear Fig. 6-7: Tow point arm adjustment [1] Tow point arm [3] Lug [2] Screws ‘Always fit tow point arms in the same position on both sides. >> Set screed on a support (if possible made of wood). >> Align the screed so that it Is horizontal by raising and lowering the tow point rams. The screed must lie flat on the support. >> Support strap [1] on the tow point arm [3]- >> Unscrew the three screws [2] on the strap [1]. >> Move the road paver In the correct position. >> Fit the middle screw. >> Place the strap [1] In the correct position by raising and lowering the tow point rem. >> Scraw on the strap [1]. The tow point arms have been adjusted and secured. joseph Vogele AG 2016 BAL_1382 212542201 en 245 / 253‘Assembly and conversion Pag Rape fo sv ENaC) [w] VOGELE 6.02 Fitting and adjusting the steering system (direc- tion indicator) cator Pivoting the direction indicator Fig. 68: ‘Steering system L141 Mounting pipe [4] Telescopic rod [21 Clamping screw [5] Clamping screw [3] Direction indicator [6] Clamping screw ‘The length of the direction indicator [3] can be adjusted and pivoted to suit the working width, >> Insert the direction indicator [3] into the mounting [1]. >> Secure direction indicator [3] with clamping screw [2]. ¥ The direction indicator has been fitted. >> Loosen clamping screw [5]. >> Pull telescopic rod [4] out of the guide. >> Tightan clamping screw [5]. ¥ The length of the direction indicator has been adjusted. >> Loosen clamping screws [2] and [6]. >> Pivot direction indicator [3] as required. >> Tighten clamping screws [2] and [6]. ¥ The direction indicator has been pivoted. The direction indicator [3] must be removed during transport. 246 / 253 BAL_1382_2125422 01 en © Joseph Vogele AG 20162 ;embly and conversion VOGELE Hounting and sonnet the balloon ight Removing the direction >> Swivel in direction indicator [3]. indicator >> Remove the direction indicator [3] from the mounting [1]. ¥ The direction indicator has been removed, 6.03 Mounting and connecting the balloon light 7g. 6-9: Mounting and connecting the balloon light [1] Switch CEE sockets switch [3] Hand rail (on or off [2] CEE sockets Mounting and connecting >> Fit balloon light to the hand rail [3] behind the driver's seats. the balloon light >> close zipper of balloon light cover. >> Plug balloon light connector into balloon light CEE sockets [2] on the heating distribution box. >> Start diesel engine. >> Switch on switch [1] on heating box. ¥ The balloon light inflates. The balloon light illuminates approx. 30 seconds after the envelope becomes rigid ¥ The balloon light has been fitted and connected. eae If the envelope is open (open zipper), the balloon light goes out. joseph Vogele AG 2016 BAL_1382_2125422 01 en 247 / 253‘Assembly and conversion COffsatting the push rollers lw] VOGELE 6.04 Offsetting the push rollers Fig. 610: Push rollars i inital position [1] Push rollers [2] Push roller beam 4 3 "ig. 614; Locking plate in nal postion [3] Fastening serews [4] Lateral locking plate ‘The push roller [1] can be offset by 2 Inch / 50 mm and by 4 Inch / 4100 mm. 248 / 253 BAL 1382 2125422 01. en © Joseph Vagele AG 2016Offsetting the push rollers VOGELE Assembly and conversion Offsetting the push roller by 2 inch / SO mm. Fig. 6-12: (Offset push roller (2 inch / 50 mm) [5] Small pin [6] Cross member Danger due to heavy load ‘The push rollers is heavy and can cause serious injurk + Always support push roller. ‘+ Wear personal protective equipment, ‘+ Ask a second person to help. “= Do not overestimate your own strength. "+ De not welk or stand in the hazard area. Offsetting the push roller >> Park road paver on firm, level ground. by 2 inch / SO mm > shut down engine and remove ignition key. >> Raise the push roller [1] using suitable lifting gear. >> Pull out small pin [5], e.g. using a screw. Warning of crushing hazard ‘Ifthe push roller is not secured, It can fall down and cause severe injuries. "= Ensure there are no people or objects in the hazard area. ‘+ Always support push roller. ‘+ Ask a secord person to help, sseph Vogele AG 2016 BAL_1382 212542201 en 249 / 253foating te patron lw] VOGELE >> Push push roller beams [2] together with the push rollers forwards, “The holes in the cross member [6] must be aligned with the rear holes in the push roller beam [2]. >> Lock the push roller beam [2] with the small pin [5]. ‘ig. 6-13: Lateral locking plate (2 Inch / 30 mm) [4] Lateral locking plate >> Loosen fastening screws [3] on the two locking plates [4] and re- move locking plates [4]. >> Tum lateral locking plates [4] by 180° and secure them using fas- tening screws [3] In the front holes of the push roller. The push roller is offset by 2 inch / 50 mm. 250 / 253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE “mint Offsetting the push rollers Offsetting the push roller by 4 inch / 100 mm. Fig. 6-14 Offset push roller (4 inch 7 100 mm) {71 Large pin ‘Danger due to heavy load ‘The push rollers is heavy and can cause serious injuries! ‘+ always support push roller ‘+ Wear personal protective equipment, ‘+ Ask a second person to help. “= Do not overestimate your own strength. "+ De not welk or stand in the hazard area. Offsetting the push roller >> Park road paver on frm, level ground. by 4 inch //00 mm > shut down engine and remove Ignition key. > Ralse the push roller [1] using suttable lifting gear. >> Pull out large pin [71 eg. using a screw © Joseph Végele AG 2016 BAL_1382 212542201 en 251/253‘Assembly and conversion panel ionecetiome lw] VOGELE ‘Warning of crushit If the push roller is not secured, It can fall down and cause severe injuries. ‘+ Ensure there are no people or objects in the hazard area, ‘+ Always support push roller. '* Ask a second person to help. It Is not allowed to make any changes to the machine that will result In an incraese In the nolse emissions. >> Push the push rollers [1] on the push roller beam [2] to the front. ‘The hole on the push roller [1] must be aligned with the front hole on the push roller beam [2]. Lock tha push roller [1] with large pin (7]. Fig. 6-15: Lateral locking plate (4 inch / 100 mm) [4] Lateral locking plate >> Loosen fastening screws [3] on the two locking plates [4] and re- move locking plates [4]. >> Turn lateral locking plates [4] by 180° end secure using fastening screws [3] In the rear boreholes of the push roller. The push roller is offset by 4 Inch / 100 mm. 252/253 BAL_1382_2125422_01_en © Joseph Vogele AG 2016VOGELE ovine REVISION ISSUES Changes to VISICN 5100-2 road paver: Date ones eEPey cern} Valid from eee 01.01.2016 2125422 01 en = Cichange joseph Vogele AG 2016 BAL_1382 212542201 en 253/253