Big-Sonic-Ski

Mounting instructions
-english-
The text and graphics of this manual have been elaborated with the greatest possible care. However, we may not be held
liable for possible errors and failure effects.
Should you wish to make suggestions regarding the arrangement of this manual or point out possible errors, please
contact your local dealer. We will gladly take up any of your ingenious ideas and suggestions.

Many company names, designations and other data used in the following examples are, unless stated otherwise, purely
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All rights reserved. This document may not be duplicated or transferred for any purpose whatsoever without MOBA’s
written consent, irrespective of the way or the means which are used.

Article-no.: 10-02-02101

Date: 07.2007

MOBA
Mobile Automation AG
Kapellenstraße 15
D-65555 Limburg
Internet: www.moba.de
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Table of contents

1. Preface ........................................................................................ 4
2. Instructions regarding safety at work ........................................ 5
3. General comments on this manual ............................................. 6
4. Scope of delivery ........................................................................ 7
5. Summary of the mechanical components .................................. 8
6. The mechanical components ...................................................... 9
6.1 Mounting the mechanical components ............................... 11
6.1.1 Mounting the tow arm brackets .................................... 12
6.1.2 Mounting the swing arms ............................................. 13
6.1.3 Mounting the middle bracket ........................................ 14
6.1.4 Mounting the module elements .................................... 16
6.1.5 Mounting the sensor brackets ...................................... 17
7. The electrical components ....................................................... 20
7.1 Mounting the electrical components ................................... 20
7.1.1 Mounting the Big-Ski junction box ............................... 21
7.1.2 Mounting the Sonic-Ski sensors .................................. 22
7.1.3 Mounting the MOBA-matic controller ........................... 23
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1. Preface

These operating instructions contain important information and advice for

mounting the Big-Ski mechanical system.
Therefore, read this manual carefully and completely.
If questions arise which cannot be settled by means of these mounting
instructions or the operating instructions of the corresponding MOBA-matic
system, please contact your supplier.

Pictographs and symbols

The following pictographs and symbols are used in this manual:

A warning triangle with exclamation mark indicates all sources of

danger which, if not avoided, may endanger the health of the operating
personnel or damage the equipment.

Instructions that must be adhered to are marked with a pointing hand.

In addition, instructions of special importance are printed in bold.

• Enumerations are marked with a black dot.

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2. Instructions regarding safety at work

General instructions

• Always switch the MOBA-matic system to manual mode before

leaving the driver’s seat or if the machine stands still.
• Never carry out any work on the sensors if the system is in
automatic mode.
• If safety-relevant machine parts have to be removed in order to
mount system components, these parts have to be put back into
place before the machine is put into operation.
• Make sure that the screed rests solidly on the ground before
you perform any work on the system.
• Adhere to the safety instructions provided by the manufacturer.

When welding

• Before welding, disconnect at least the negative pole of the

machine battery and, if possible, dismount all electronic
components or disconnect their power supply. Arc welding
creates very strong currents which may destroy the machine’s
electronic system.
• Place the negative electrode of the welding outfit close to the
point where the weld is to be.
• Remove the varnish from the intended fixing point and the
holding device to be welded on. Prime and lacquer the weld
seams when the job is done.
• Protect combustible parts from flying sparks.
• Never look into the arc without wearing safety glasses.
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When mounting

When mounting the Big-Ski it is essential that neither the free

movement of the tow arm nor the free movement of the screed
construction is impaired by any attachment parts; i.e an un-
obstructed movement must be guaranteed over the whole working
range!

3. General comments on this manual

These mounting instructions only deal with the mechanical mounting, including
the mounting of all components. This manual is meant as a supplement to the
MOBA-matic operating instructions. As a consequence, these mounting instruc-
tions do not describe how to operate and work with the Big-Ski.
Please refer to the corresponding operating manual for all information that goes
beyond the mounting of the Big-Ski mechanical system.

The MOBA-matic system can be obtained in two different versions. Depending

on the MOBA-matic system used, one of the three operating manuals which are
described in greater detail below is to be used as a reference.

Article-no.
Example: Title of the manual
of the manual

MOBA-matic, CAN
Operating instructions version 4.28-005 10-02-00855
or
Operating instructions version 4.28-2044 10-02-00861
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Article-no.
Example: Title of the manual
of the
manual

MOBA-matic, with Big-Sonic-Ski

Supplement to the operating instructions 10-02-00811
MOBA-matic version 3.xx

4. Scope of delivery

The scope of delivery may differ, depending on the length of the modularly
designed Big-Ski. However, all mechanical system components and all screws
needed for fixing the relevant attachment part are always included in delivery.
The electrical components and the corresponding cables are not included in
delivery.
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5. Summary of the mechanical components
5

2
3
2
4
7
5
10

1
7

6
2

3
4

Komponente Bezeichnung Artikel-Nr. Anmerkung

Pos.
components designation article no. remark
Mittelelement
1 04-05-00740 L = 2500 mm
Middle bracket

Modulelement
2 04-05-00741 L = 2100 mm
Module element

Sensorhalter, erweiterbar
3 04-05-00742 L = 1080 mm
Sensor bracket, extensible

Sensorausleger
4 04-05-00743 L = 1500 mm
Sensorboom, extension arm

Schiebehalter für Sensorhalter

5 04-05-00744
Sliding bracket, for sensor brackets

Sensorhalter
6 04-05-00769 L = 1000 mm
Sensor bracket

Schwenkarm
7 04-05-00764 L = 800 mm
Swing arm

Fixierring, für Sensorhalter

8 04-05-00745 Ø 45mm
Clamp collar, for sensor brackets
Fixierring, für Schwenkarm
9 04-05-00746 Ø 50mm
Clamp collar, for swing arm
Halteplatte, für Verteilerbox
10 04-05-00760
Mounting plate, for junction box
11 Kreuzgriffschrauben 01-17-02805 M8-20
12 Star knob screw 01-17-02806 M10-30
Schraube für Verteilerbox
13 01-01-00178 M6x12
Screw for junction box
Schraube für Schwingarm
14 01-01-00553 M16x55
Screw for swing arm
Schraube für Modulelement
15 01-01-00631 M10x70
Screw for module element

Halterung Zugarm vorn

16 on request must be adapted to the tow arm
Tow arm bracket front
Halterung Zugarm hinten
17 on request must be adapted to the tow arm
Tow arm bracket back
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6. The mechanical components

The mechanical design is of great importance for the realisation of the Big-Ski
system.
Since the sensor bracket may be very long at times, it should be very solidly built
and screwed tightly to the tool bracket. Furthermore, it is advisable to divide the
system into several components in order to facilitate transport and mounting.
The points mentioned above have been taken into consideration; this resulted in
the development of a system which can be mounted or dismounted quickly and
easily.
The long beam construction has been divided into small components which can
be modularly adapted; i.e the length of the Big-Sonic-Ski may differ, depending
on the combination of the attachment parts.

Combining one middle bracket and two module elements with the sensor booms,
for example, results in a total Ski length of about 9,30 m at the maximum.
When combining one middle bracket and four module elements with the sensor
booms, a total Ski length of 13,50 m at the maximum may be realised.
The following sections deal with the mounting of the long version, as the shorter
version can be easily created by leaving two module elements out.

In addition, it has proven useful to adjust the alignment of the individual sensors
above the reference by using the special sensor booms at the front and at the
back (quite often, Sonic-Skis are positioned in front of or behind the machine so
that a reliable sensing of the reference is guaranteed in curves, too).
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X1 X2

Ideally, the distance between the sensors is identical (X1 = X2).

The middle sensor is mounted at the same position where a single sensor would
be fixed, so that, if required, you may choose to work with only one sensor by
simply using the sensor select menu on the MOBA-matic controller (for example
at the beginning of the paving, at a road junction, etc.).

Depending on the application, the mechanical system may be mounted either in

a sideways position beside the screed or above the screed. The mounting
position depends on the mounting width required.
The mounting procedure is identical in both cases.
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6.1 Mounting the mechanical components

The sections below describe how and in which order the individual components
of the modularly designed Big-Ski are mounted.

In order to ensure that the Big-Ski may be operated as parallel to the ground as
possible, it must be mounted with due consideration of subsequent paving con-
ditions.
For this purpose, the screed should be positioned at the level corresponding to
the desired thickness of layer and the tow point should be set accordingly.
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6.1.1 Mounting the tow arm brackets

Caution:
When mounting the two tow arm brackets it is essential that they do
neither restrict the free movement of the tow arm nor the free
movement of the screed construction; i.e. an unobstructed movement
must be guaranteed over the whole working range!

The whole Big-Ski system is mounted on the tow arm in a sideways position.
For this purpose, the two tow arm brackets have to be mounted first.
Depending on the paver used, the design of the tow arm brackets may some-
times differ.
During mounting, the brackets may either be screwed tightly to the existing drill
holes or they may be fixed to the tow arm with clamping plates, as shown in the
picture below.
Alternatively, the two brackets may also be welded on directly.

The tow arm bracket front is mounted

directly behind the tow point.
Make sure that the bracket stands in
an upright position.
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The tow arm bracket back is mounted

in a position where it is about level with
the auger.
Make sure that the bracket stands in
an upright position.

In this context it should be pointed out

once again that the attachment parts
must not obstruct or even block the tow
arm, irrespective of the tow arm’s pos-
ition.

6.1.2 Mounting the swing arms

Before the swing arms can be attached to the two tow arm brackets, the two
clamp collars must be mounted.

Caution: Push the clamp collars over

the tow arm brackets with the 45°
bevel facing upwards and fix the
clamp collars with the M10 star knob
screw.
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Afterwards push the two swing arms

over the tow arm brackets.
The swing arm at the back is turned
180° before being attached to the tow
arm bracket, as can be seen in the
picture.

6.1.3 Mounting the middle bracket

The middle bracket is the first crucial component of the whole Big-Ski system.
Two sliding brackets which must be pushed over the two round center pivots on
the swing arms have already been mounted by the manufacturer.

Begin the mounting procedure,

however, by pushing a clamp collar
(flat type) over the swing arm at the
front and fix it with the help of the M10
star knob screw.
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Now the middle bracket is mounted.
When mounting the middle bracket it is
essential that the round pivot to which
the remaining modules will be hitched
at a later stage is facing upwards.

Begin by pushing the sliding bracket at

the back over the swing arm at the
back from below.
Then lift the middle bracket together
with the swing arm at the back to a
position where the sliding bracket at
the front can be pushed over the swing
arm at the front from above.

Finally secure the sliding bracket at the

back with a clamp collar and a M10
star knob screw.

When the first component of the Big-Ski has been mounted, it has to be aligned:
- Align the middle bracket horizontally by using the clamp collars on the
swing arms and, if necessary, the clamp collars on the tow arm brackets.
- Then align the middle bracket parallel to the paver by turning the swing
arms.
Finally secure all fastening screws.
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6.1.4 Mounting the module elements

To mount the other module elements,

simply attach the remaining elements
with the hook.

Secure each module element with the

help of a M10 x 70 locking screw after
it has been attached.

It is now possible to mount up to four

module elements by following this
mounting procedure.
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6.1.5 Mounting the sensor brackets

Mounting the module elements completes the Big-Ski beam construction.

Now the sensor brackets into which the Sonic-Ski sensors can be inserted at a
later stage are mounted.
As stated earlier in this manual, the middle sensor should be mounted on the
Big-Ski beam construction at exactly the same position where it would normally
be fixed (approximately level with the auger).
The two outer sensors should be mounted at an identical distance from the
middle sensor.

For the purpose of mounting the

sensor brackets, three sliding brackets
are slid onto the beam construction.
(one sliding bracket on the middle
bracket and one sliding bracket each
on the two outer module elements).
The sensor brackets are inserted into
the sliding brackets from below and
secured with the two M10 star knob
screws.

In addition, all sensor brackets are

secured with a clamp collar.
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So-called “extensible sensor brackets“ are mounted at the two outer positions,
whereas a conventional sensor bracket is fixed to the middle of the beam con-
struction.

A so-called “sensor boom“ each is in-

serted into the two outer “extensible
sensor brackets” from the outside.

After mounting, all components must be fixed with M10 star knob screws.

Tipp:
If there is not enough room for inserting the sensor brackets from
below, simply lift the screed slightly off the ground with the help of the
transport cylinders.
As soon as the sensor brackets have been mounted, the screed must
be placed solidly on the ground once again in order to avoid risking
accidents.
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Mounting the sensor booms completes the mounting of mechanical components.

Example: a Ski length of

9,30 m

Example: a Ski length of

13,50 m
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7. The electrical components

7.1 Mounting the electrical components

Only Sonic-Ski sensors with a CAN-interface can be used in con-

junction with the Big-Sonic-Ski.
(These sensors are recognizable by the bayonet type connector instead of the
standard screw type connector)

The Big-Ski system consists of the following electrical components:

- three Sonic-Ski sensors with a CAN-interface,
- one junction box,
- one MOBA-matic controller
- and the corresponding connecting cables.

The following drawing shows the position of the three sensors within the system:

1 2 3

1 (front) 2 (middle) 3 (back)

In order to ensure that the sensor positions are identical on both sides of the
machine, it has to be taken into account, when mounting the junction box, that
the input plug at the side which is used for connecting the MOBA-matic controller
is always pointing in the direction of travel (forwards).
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Only in this way it can be guaranteed that the sensor signals indicated on the
MOBA-matic controller really correspond to the actual sensor position.

7.1.1 Mounting the Big-Ski junction box

The junction box should be mounted in a way that a simple wiring to the
controller and the sensors is possible. The connectors for the sensors should
always point downwards, so that no water can penetrate into the junction box. All
inputs that are not used have to be sealed with dust protection caps.
As described earlier, the input plug is always pointing in the direction of travel
(forwards).

1. step:
The junction box is mounted on the
mounting plate by means of the M6x12
hexagon socket screws.

2. step:
Then the mounting plate is mounted on
one of the two middle sliding brackets
with the M8 star knob screws.

Be careful when mounting the Big-Ski on the right side of the machine:
In order to meet the requirement that the input plug must always be pointing in
the direction of travel, the sliding bracket onto which the junction box is to be
mounted must be slid onto the Big-Ski from the inside to the outside.
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7.1.2 Mounting the Sonic-Ski sensors

The Big Ski always uses the ground as a sensing reference; i.e. the sensors
must always be aligned in the direction of travel.

This picture shows the Sonic-Ski sen-

sor mounted in middle position.

On the two outer sensor brackets the

sensor may also be mounted on the
swiveling sensor booms.
In this way it becomes possible to
swivel the two outer sensors during
mounting for different purposes such
as driving along curves, for example.

If a sensor boom is swiveled sideways,

it must be taken into account that the
mounted sensor must eventually be
realigned in the direction of travel.

The sensors are secured with M8 star knob screws.

For this purpose, two star knob screws are provided for each sensor.
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7.1.3 Mounting the MOBA-matic controller

The MOBA-matic controller is inserted

into the already existing holder.

Mounting the electrical components completes the mounting of the Big-Sonic-

Ski.

The next steps would be the wiring and the putting into operation of the system.
Please refer to the relevant operating instructions for any information on the
necessary steps to be taken.