Training Machine Technology M3 Super 1400

Publisher
Wirtgen India Private Limited
GAT No 301 & 302
Bhandgaon- Khor Road, Bhandgaon
Tal- Daund, Dist- Pune 412214- India

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Training Contents

Contents

1.0. General Information

2.0. Machine operation

3.0. Machine components, hydraulic system

4.0. Machine components, electrical system

5.0. Control system

6.0. Settings and measured values

7. 0 Jump starting / welding

8.0. Engine

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 1. General Information

1.0. Machine operation

1.1. Type/ Designation/ Hi Lights
1.2. Performance data
1.3. Measurements
1.4. Product Identification Number
1.5. Paver Operator console/ Lateral console
1.6. Engine

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1. 1-General Information / Type Designation / Highlights

• New SUPER 0763 series launched in December 2016

• Type designation 0763 followed by the serial number e.g. 0763 0020

• The paver is coming with the new Ergo Basic operating concept

• AB480TV Screed is fitted

• One Main controller (PCB) is part of Operator Main Console

• Only 1 Bodas controller from Bosch-Rexroth (RC32) used

• CAN Nodes / Retain Memory (USB Stick)/ Mother board or

Power PC- are not used

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1.2- General Information Performance Data

Description Super 1400

Maximum Operating Weight 17400 kg

Transport Width 6.035 m

Engine Cummins
Type B 5.9 150C 31(BSIII)
(Liquid cooled, 6 cylinder, mechanical diesel engine)
Output (kw /ps / hp) 112kw/152ps /150hp @ 2200 rpm
Modes Min & Max
Fuel Tank 220 liter

Screed Type AB 480 TV (29 AB)

Basic width 2.55 m to 4.8 m
Paving width Max 7.3 m
Paving Thickness Upto 30 cm
Electrical System 24v dc
Operating system Ergo Basic

Under Carriage
Crawler Rubber shoes

Travel drive Hydraulical, Independent, Electronically controlled,

1 stage Gear box

Driving speed Paving 2 to 24 mtr/ min

Marching- 4.5 km/ hr
Material Transport Hopper capacity 13 t
Hopper length 1912 mm (to axle push roller)
Hopper loading height 510 X 560 mm
Auger speed 83 rpm
Laydown rate Max (theoretical) 600 ton / hour

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1.3- General Information Measurments

Description Super 1400

Measurements
Length 6035 mm
Height 3649 mm
Width 3267 mm

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1.4-General Information / Product Identification Number

S- Super series A- CL ( Check Letter), Unique for a

140- Machine Size defined machine serial number 0763- Machine Series
0- Crawler Mounted
Machines

›W V B S 1 4 0 0 A 07 6 3 0 0 2 0‹

WMC- World Manufacturer Code, WVB- it is a code 0020- Machine serial number
for Vögele machines build in Wirtgen India

On Chassis- RH side of operator cab

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1.5-General Information – Paver Operator console & Lateral console (Remote)

Operator Main Console- Ergo Basic

Lateral consoles (Remote)

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1.6-General Information – Diesel Engine

Cummins engine
• Model B5.9 six-cylinder in-line Engine
• Rotary fuel system
• 5.9 L displacement
• Emission- BS III
• Waste gated turbocharger
• Liquid cooled
• Min RPM- 900 + 50
• Max RPM- 2200
• Eco mode- Not available
• Rated output- 150 hp / 112 KW @ 2200 rpm
• Direct Fan drive
• Fail Safe coupling

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 2. Machine Operation

2.0. Machine operation

2.1. Paver operator's console
2.2. Paver operator's console overview
2.3. Lateral console / Remotes
2.4. Sensors

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 2.1.- Machine Operation / Paver Operator console

Operator Main Console

Hour meter ( LH side of main console)

Ignition Key (RH side of main

console)
On-Off-On 3 way position

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 2.2- Machine Operation / Paver Operator Main console Over view

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 2.2.1- Machine Operation / Operator Main console Night view

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 2.2.2- Machine Operation / Operator Main console Explanation

Vibration Set point reading LEDs

Automatic / Override/ Vibration / Tamper
Both conveyor
Set point adjustment
reverse
Tamper
Automatic / override/ Horn
Conveyor LH Conveyor RH
Automatic / Set point adjustment
Automatic/
Override Over ride
Hopper LH
Open / Close

Hopper RH
Open / Close

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 2.2.3- Machine Operation / Operator Main console Explanation

Tow point LH
Auger LH Automatic/ Raising / Lowering
Override/
Set point adjustment
Tow point RH
Automatic Raising / Lowering
Filling

Set point reading

Auger LH/ RH Warm up /
Screed Lowering / Raising Cleaning function

Auger RH
Automatic/ Override/
Screed width control LH Screed width control RH Screed Heating
Set point adjustment
ON/OFF

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 2.2.4- Machine Operation / Operator Main console Explanation

Beacon

Working light 24V DC

Indicator Fine steering

Diesel Engine
START/STOP

Fine steering
Diesel Engine
Mode Selection

Steering

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 2.2.5- Machine Operation / Operator Main console Explanation

Fuel level Indicator

5 LED >88%
4 LED >63%
3 LED >38% Counter rotation
2 LED >13%
1 LED > 6%
1 LED flashing < 5%

Preselection button
Travel direction
Forward (white)/
Backward (red)

Potentiometer -
Pave & Transport speed

Traction Main Switch

Mode Selection
Indicators / Warnings Pave / Positioning / Transport/ Neutral

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 2.2.6- Machine Operation / Operator Main console - Warning Symbols & LED indiactors

Alphabet Details
A Diesel Water separator full
B Hydraulic - Leakage oil filter clogged[1]
Hydraulic- Return oil filter clogged [2]
C Collective error indication [e.g. Sensor conveyor, etc.]
A B C D E
D Status indicator preheating - Engine

E Parking brake pedal- Pressed

F G H I J F Engine oil- Low pressure (LLOP)

G Alternator or D+ faulty
K L M N H I Series Engine ( not applicable)
I I Series Engine ( not applicable)
O P Q R J I Series Engine ( not applicable)
K Reserve
L Insulation fault
M Coolant level - low
N Air filter clogged
Selected / Status OK
Needs attention O Parking brake engaged

Needs Immediate attention / Stop P Reserve

machine Q Coolant temperature too high

R Engine failure (2 priorities)

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 2.3- Machine Operation / Lateral console (Remote)

Console double,
to connect screed console
and Niveltronic Basic.
Console single,
to connect screed console
only.
Sensor
connectors

Screed
console and
Niveltronic
Basic
connectors

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 2.3.1- Machine Operation / Lateral console (Remote)- Explanation

LED Warning
Conveyor over ride Conveyor - Override

Horn

Conveyor
Automatic

Setpoint level Screed - Floating position

Auger – Automatic / Setpoint

Increase / Decrease

Tow point - Raising

Auger - Reverse
Tow point - Lowering

Auger – Over ride

Screed width control

(Extend / Retract)

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 2.3.2- Machine Operation – Niveltronic basic

LED cross - levelling Niveltronic Basic (Sensors)

ON / OFF

Present Sensor sensitivity

0 = Very slow Set value
5 = Standard / Medium
9 = Very fast

Sensitivity selection
Actual value
Sensor / Mode selection

Selected sensor / Mode type

Sensor Quick set up Sensor calibration

Set point (Increase / Decrease)

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 2.3.3- Machine Operation – Niveltronic basic - Nigh view

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 2.4. Machine Operation – Ultrasonic Sensor Auger

LED lights

Set value filling level

Ultrasonic sensor

Sensor connection (7 Pins) Set value filling level

Increase material supply

LED too much material

LED balanced material supply

LED too less material

Decrease
Decrease material supply material supply Increase material supply
Quick adjustment

LED balanced material supply

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 2.4.1- Machine Operation – Mechanical Grade Sensor

The LED light illuminates

the working area. If both centre LED
lights are lighting up, it indicates that
the sensor is set to 45°.

This serves to facilitate setting (Set up

assistant). With this setting we are
getting the biggest possible working
range.

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 2.4.2- Machine Operation – Slope Sensor

Sensor symbol Sensor type

No sensor connected

Mechanical
grade sensor (old)

Mechanical grade sensor, variable

Scanning the ground

Mechanical grade sensor, variable

Scanning a tensioned wire

Slope sensor
Slope to the right

Slope sensor
Slope to the left

Sonic grade sensor

Scanning the ground

Sonic grade sensor

Scanning a tensioned wire

The machine connection for the slope sensor is located in harness – W1 and is plugged into socket +7-B14.X1s (Deutsch 3-pole plug connector).

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 [Link] Components – Hydraulics System

3.0. Machine components, hydraulic system

3.1. Topology 3.11 Hydraulic Motor, HM1_HM2

3.2. Components Description 3.12. Hydraulic Motor, HM3_HM4_HM5_HM6
3.3. Right-hand side of machine 3.13 Valve block –HA1, Cyl function Levelling
3.4 Operators stand 3.14. Valve block –HA2, Cyl fn_Hopper, Screed
3.5 Left-hand side of machine 3.15. Valve block –HA3, Auger
3.6 Pumps position 3.16. Valve block –HA4, Conveyor
3.7. Traction System 3.17. Valve block –HA5, Vibrator
3.8. Hydraulic Pump- HG1 & HG2 3.18 Valve block –HA6, Tamper
3.9. Hydraulic pump, HG3 3.19 Hand pump- HG12, Brake release
3.10. Hydraulic pump, HG6_HG7_HG8_HG9 3.20 Hydraulic filters

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 3.1 Machine Components – Hydraulics Components Topology

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 3.2 Machine Components – Hydraulics Components Description

Pump Group (HG) Motor/ Cylinder Group (HM) Valve block Group ( HA)
Name Function Name Function Name Function
HG1 Adv drive LH HM1 Adv drive LH HA1 Cyl (Tow point)
Hopper C yl, Screed cyl
HG2 Adv drive RH HM2 Adv drive RH HA2 (Raise/lower, Extd/ Retr)
HG3 Auger HM3 Auger LH HA3 Auger
HG4 Conveyor LH HM4 Auger RH HA4 Conveyor
HG5 Conveyor RH HM5 Conveyor RH HA5 Vibration
HG6 Tamper HM6 Conveyor LH HA6 Tamper
HG7 Vibration HM7 Tow point RH
HG8 Cylinder functions HM8 Tow point LH
HG9 Supply Auger HM9 Screed (low/raise)
HM10 Screed (low/raise)
HM11 Hopper Filter Group (HV)
HM12 Hopper Name Function
HV1 Leak return
HV2 Combination
HV3 Breather

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 3.2 .1 Machine Components – Hydraulics Components Description -Pump Group

Pump No Part No Sheet no Functions

HG1 2384012 6.5 Advance drive- LH
HG2 2384012 7.5 Advance drive- RH
HG3 2384021 9.2 Auger
HG4 2395661 10.2 Conveyor- RH
HG5 2395661 10.3 Conveyor- LH
HG6 2384060 13.3 Tamper
HG7 2384060 13.4 Vibrator
HG8 2384060 9.1 Cylinder functions (Levelling, Screed)

HG9 2384060 9.1 Steering

HG12 2405098 8.6 Parking brake release

Similar Part no’s

HG1 & HG2- 2384012
HG4 & HG5- 2395661
HG6, HG7, HG8 & HG9- 2384060

Ref HFP_0763_2535435_00_00_00

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 3.2 .2 Machine Components – Hydraulics Components Motor / Cylinder Group

Motor/ Cyl No Part No Sheet no Functions

HM1 2384037 6.1 Adv drive motor- LH
HM2 2384037 7.1 Adv drive motor- RH
HM3 2392628 9.5 Auger motor- LH
HM4 2392628 9.6 Auger motor- RH
HM5 2392628 10.2 Conveyor motor- LH
Similar Part no’s
HM6 2392628 10.5 Conveyor motor- RH
HM1 & HM2- 2384037
HM7 2391777 11.4 Tow point cylinder- RH HM3, HM4, HM5 & HM6
- 2392628
HM8 2391777 11.6 Tow point cylinder- LH
HM7 & HM8- 2391777
HM9 2391803 12.2 Screed Cylinder HM9 & HM10- 2391803
HM11 & HM12- 2391796
HM10 2391803 12.3 Screed Cylinder
HM11 2391796 12.4 Hopper cylinder
HM12 2391796 12.5 Hopper cylinder

Ref HFP_0763_2535435_00_00_00

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 3.2 .3 Machine Components – Hydraulics Components Control Valves group

Control Valve No Part No Sheet no Functions

HA1 2405111 11.1 Cylinder functions (Levelling system)
HA2 2405110 12.2 Cylinder functions (Screed, Hopper)
HA3 2405100 9.4 Auger
HA4 2405106 10.3 Conveyor
HA5 2405109 14.3 Vibrator
HA6 2405109 13.4 Tamper

Similar Part no’s

HA5 & HA6- 2405109

Ref HFP_0763_2535435_00_00_00

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 3.3 Machine Components – Hydraulics System- Right hand side of machine

Parking brake release

pump HG12
Hydraulic Pumps

Auger Motor

Tow point
cylinder

Advance drive motor

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 3.4 Machine Components – Hydraulics System, Operator Stand

HA8- Front wheel drive

HA4- Conveyors

HA1- Tow point

Cylinders

HA2- Hopper HA3- Augers

HA5- Vibrator

HA6- Tamper
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 3.4.1 Machine Components – Hydraulics System, Operator Stand

HA1- Tow point

HA2- Hopper
Cylinders

HA4- Conveyors

HA3- Augers

HA5- Vibrator HA6- Tamper

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 3.5 Machine Components – Hydraulics System, LH Side

HA1
Tow point HA2
cylinder

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 3.6 Machine Components – Hydraulics System, Pump position

 5-Output gear Box

 Coupled with Engine
 4-output for Hydraulic Pumps
 1-Output for generator drive

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 3.6.1 Machine Components – Hydraulics System, Pump position

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 3.6.2 Machine Components – Hydraulics System, Pump position

F- HG3- Auger
F- HG1- LH Adv drive

M- HG6- Tamper R- HG4- LH Conveyor

R- HG7- Vibration
F- HG8- Cylinder functions

F- HG2- RH Adv drive R - HG9- Steering &

Supply Auger
R- HG5- RH Conveyor

F- Front M- Middle R- Rear

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 3.7 Machine Components – Hydraulics System, Schematic- Traction drive system

Hydrostatic traction drive in the SUPER 1403 is

effected via 2 separate hydraulic drive units.
Variable displacement axial piston motors are
installed in each of the crawler tracks and each
are driven by a variable displacement axial piston
pump. Adjustment of the traction motor is
feed pressure / control
pressure effected by an electrically actuated proportional
leakage oil valve. The actual speed of each motor is
speed sensor
determined via speed sensors installed in the two
traction motors. Set point and actual values are
constantly compared via the electronics.
Any difference between set speed and actual
speed is compensated by increasing or reducing
the control current to the pumps for traction. This
is referred to as a closed control loop. If one or
both sensors fail, the maximum speed is
reduced. However, the sensor system can also be
bypassed by switching to manual traction drive
proportional high / low pressure mode in order to complete the job site. The paver
valve pump leakage oil
will then travel at reduced speed, but without
proportional valve motor
control.

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 3.8 Machine Components – Hydraulics System, Hydraulic Pump, Traction drive- LH(HG1)_RH (HG2)

A4VG48
#2384012

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 3.9 Machine Components – Hydraulics System, Hydraulic Pump- Auger- HG3

A10VO45DFR1
#2384021

260 Bar

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 3.10 Machine Components – Hydraulics System, Hydraulic Pump- Tamper_Vibrator_Cylinder fn_Steering
HG6 HG7 HG8 HG9

AZPFF-22-019_16LPR2020PB
#2384060

HG8- Cylinder functions-

Tow point cylinder LH&RH
Hopper cylinders
Screed cylinder (Low, raise, Hold & Float)

HG
6 HG
8

HG
HG
9
7

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 3.11 Machine Components – Hydraulics System, Hydraulic Motor , Traction drive- HM1_HM2

A6VE60
#2384037
HM1-Adv drive LH
HM2- Adv drive RH

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 3.12 Machine Components – Hydraulics System, Motor_ Auger_Conveyor_HM3_HM4_HM5_HM6

OMSS160
#2392628

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 3.13 Machine Components – Hydraulics System- Valve block_ Cyl function levelling_ HA1

#2405111

HA1HQ1-Levelling system- RH

HA1HQ2-Levelling system- LH

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 3.14 Machine Components – Hydraulics System- Valve block_ Cyl function_Screed_Hopper_HA2

#2405110

HA2HQ3- Hopper Closing & Opening

HA2HQ3
HA2HQ2- Screed Lowering/ Raising

HA2HQ2

HA2HF1

HA2HQ1- Screed Hold

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 3.15 Machine Components – Hydraulics System- Valve block_Auger_HA3

#2405100

HA3HQ1-Auger LH Fwd/ Rev HA3HQ1

HA3HQ2-Auger RH Fwd/ Rev

HA3HQ2

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 3.16 Machine Components – Hydraulics System- Valve block_Conveyor_HA4

#2405106

HA4HQ1-Conveyor RH HA4HQ1 HA4HQ2 HA4HQ2-Conveyor LH

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 3.17 Machine Components – Hydraulics System- Valve block_Vibrator_HA5

#2405109

HA5HR2 HA5HQ1 Vibration control valve

HA5HF1

HA5HR1

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 3.18 Machine Components – Hydraulics System- Valve block_Tamper_HA6

#2405109

HA6HR2 HA6HQ1- Tamper control valve

HA6HF1

HA6HR1

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 3.19 Machine Components – Hydraulics System- Hand Pump- HG12/ Brake release Manually

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 3.19.1 Machine Components – Hydraulics System- Hand Pump- HG12/ Brake release Manually

HG12HR1

To release parking brake manually, Tighten HG12HR1 fully inside. Pump with the hand pump till the time pressure reaches the pressure
limiting valve value in the pump block or pressure gauge shows the value of 50 bar at the measuring port on HG 12.
Back off the high pressure valves (4 valves) in the traction drive system 3-4 turns! This allows the hydraulic oil to circulate between pump and motor!
The paver must not be towed more than 300m. The maximum towing speed should not exceed 10m/min.
Once towing is completed, bring HG12HR1 to its original position by loosen the same.

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 3.20 Machine Components – Hydraulics System- Hydraulic filters Over view

-HV3 oil filler port / tank vent

Level Indicator

HV2 –Intake + Return flow

filter & Bleed screw

After changing the filter or hydraulic oil, the intake/return flow filter must be bleed out. Otherwise air may be drawn into the hydraulic
system.
Before starting the machine, Loosen the bleed screw to 3 - 4 turns, then start the diesel engine and let it idle. The mixture of oil and
air emerging from the bleed screw can be collected with a rag or similar. As soon as bubble-free hydraulic oil emerges, the bleed screw
must be securely tightened down again.

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 3.20.1 Machine Components – Hydraulics System- Suction cum return Oil filter – HV2

return flow port

pressure switch 1,8 bar

return flow port

return flow port
suction port

oil outlet

suction port

oil outlet
bleed screw

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 Machine Components – Electrics

Summary of chapter

4.0. Machine components, electrics

4.1. Location description

4.2. Main Control
4.3. Controller C2
4.4. Fuel level sensor
4.5. Summary 24VDC distribution box
4.6 Central PC Board +2-A2
4.7. Fuses
4.8. Main Fuses
4.9. Relay and LED´s
4.10. Emergency Stop
4.11. Sensor amplifier +2-T5
4.12 Screed Heating
4.13 Generator
Ref ESP_0771_2541190_00_00_00

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 4.1 Machine Components – Electrics, Location description

The first number in the equipment identification represents the location of the component, e.g. +6-E5: +6
is the operator's platform; E is the device identifier; 5 is a consecutive number.

+1 Engine, +6 +5 Box for screed

engine compartment Operator's heating
platform

+9 Screed

+8 Rear of tractor unit

+7 Interior

+3 Control console +2 Control cabinet +4 Interface: screed

control, / grade and slope
control

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 4.2 Machine Components – Electrics, Main Control

+3-A1.X1s Main Control

+3-A1.X1p
Main Control

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 4.2.1 Machine Components – Electrics, Main Control

+3-A1.X1s Main Control

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 4.2.2 Machine Components – Electrics, Main Control

+3-A1.X1s Main Control

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 4.3 Machine Components – Electrics, Controller C2 / Screed Heat Control

Location- Below RH Side Operator seat, next to

Controller C2 screed heat control box
(Bodas RC36)

+7-K2.X2p
controller 2
Screed Heat control box

+7-K2.X1p
controller 2

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 4.3.1 Machine Components – Electrics, Controller C2

+7-K2.X1s +7-K2.X2s

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 4.4 Machine Components – Electrics, Fuel Level Sensor

The fuel level sensor is a Capacitive technology not a

float lever.

Capacitive technology sensors are designed to

accurately sense the fuel level. No moving parts or
floats. New mathematical filtration measuring
technology.

Measurement in between- Pin no 1 & Pin no 3

Tank full = 0.684 mega ohms
Tank Half full /empty= 0.694 mega ohms
Tank Empty= 0.702 mega ohms

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 4.5 Machine Components – Electrics, Summary 24VDC distribution box/ WIDIAG access

+2 –A2 Central PC board

+2-S5
+2-X90s Advance drive
WIDIAG access+2-X90s
point (Auto/ Manual) mode selection
WIDIAG access point

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 4.6 Machine Components – Electrics, Central PC Board +2 –A2, WIDIAG Access point

# 2434624- W77 Cable

#2024768 Peak dongle

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 4.6.1 Machine Components – Electrics, Central PC Board +2 –A2

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 4.7 Machine Components – Electrics, Fuses

Group Fuse Name Function Page No.

B+ +2 - A2.F_Test Fuse test /15.4
B+ +2 - A2.F1 25A StVZO Supervision module ID16 /16.1
B+ +2 - A2.F2 5A Open interface 1: WIFMS, Open interface 2: Navitronic light, WITOS, WIDIAG (all optional), Supervision module /16.2
B+ +2 - A2.F3 5A Ignition switch /16.3
L+C2 +2 - A2.F4 5A C2 power supply /17.1
L+ +2 - A2.F5 5A Sensors power supply, filter monitoring, fuel level indicator, air filter, level sensors, RPM-sensors /17.4
B+ +2 - A2.F6 1A Water seprator sensor /16.4
B+ +2 - A2.F7 25A Working light /16.5
B+ +2 - A2.F8 25A Reserve (ECM power supply, fuel pump power supply, Supervision module ID12) /16.6
L+C2 +2 - A2.F9 25A C2 power supply /17.2
L+C2 +2 - A2.F10 25A C2 power supply /17.3
L+ +2 - A2.F11 5A Main control power supply /17.5
L+ +2 - A2.F12 5A WL Coding /17.6
L+ +2 - A2.F13 5A Signal Ignition- Supervisor StVZO module /17.7
L+ +2 - A2.F14 7.5A Screed control RHS /17.8
L+ +2 - A2.F15 5A Reserve /18.1
L+ +2 - A2.F16 10A Reserve /18.2
L+ +2 - A2.F17 10A Pressure Monitoring, Engine RPM Sensor /18.3
L+ +2 - A2.F18 10A Reserve /18.4
L+ +2 - A2.F19 10A Horn /18.5
L+ +2 - A2.F20 7.5A Steering angle sensor,Brake pedal /18.6
L+ +2 - A2.F21 7.5A Screed heating box /18.7
L+ +2 - A2.F22 7.5A Open interface 1: WIFMS, Open interface 2: Site management, WITOS, WIDIAG /18.8
L+NA +2 - A2.F23 10A External leveling system (AGS) /20.1
L+NA +2 - A2.F24 10A Options relays /20.2
L+NA +2 - A2.F25 10A Starter /20.3
L+NA +2 - A2.F26 7.5A Reserve /20.4
L+ +2 - A2.F27 7.5A Screed control LHS /19.1
L+ +2 - A2.F28 7.5A Slope sensor /19.2
L+NA +2 - A2.F29 15A 24V power outlet /20.5
L+NA +2 - A2.F30 15A Reserve /20.6
L+NA +2 - A2.F31 15A Reserve /20.7
L+NA +2 - A2.F32 15A Reserve /20.8
B+ = continuous voltage
L+ = key on (ignition)
L+C2 = key on and C2 has been energized
L+NA = key on and emergency off circuit OK

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 4.8 Machine Components – Electrics, Main Fuses

Telematics Control Unit- GPS

tracking

Fuse +7-F101 300A

alternator and starter

Fuse +7-F103 80A

main fuse, central PC board

Fuse +7-F102 80A, Engine

speed adjustment
Not applicable

High current fuse

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 4.9 Machine Components – Electrics, Relays & LED‘s

List of relays
Relay Purpose Page no
+2-A2.K1 Battery main switch /14.6
+2-A2.K2 Release C2 (L+ C2) /14.4
+2-A2.K3 Reserve /48.2
P3 +2-A2.K4 Working lights /6.1
+2-A2.K5 Release Emergency Stop /26.2
+2-A2.K6 Release Emergency Stop /26.4
+2-A2.K7 Horn /5.2
+2-A2.K8 Propel system activation /58.2
+2-A2.K9 Reserve /45.5
K8 K10
+2-A2.K10 Emergency stop /24.7
+2-A2.K14 Power supply Screed control /31.8
R31 R30 +2-A2.K15 Starter 7.1/7.4
+2-A2.K18 Reserve 49.7

+1-K12- Removed

K7 K18
List of LEDs
K9 K15K14 K3 K4
Relay Purpose Page no
P Test
+2-A2.P Test Fuse tester /15.4
+2-A2.P1 Ignition /14.3
+2-A2.P2 K1 energized /15.5
P5
+2-A2.P3 MC/NOT+0 with 24V power (INH/C2 =1) = E-Stop circuit OK /24.7
P4 K6 K5 K1 K2 +2-A2.P4 NA_ZW with 24V (K5 energized) /25.4
P1 +2-A2.P5 L+NA with 24V (K6 energized) /25.5
P6 +2-A2.P6 K2 energized /15.7
P2

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 4.10 Machine Components – Electrics, Emergency Stop

The Emergency Stop relays K5

+7-F10 3_ 80A
and K6 are monitored via
B+
controller 2. The controller
Main control +2-A2.F3 monitor via inputs ID10 and
ID11 whether or not a relay
QD5
contact is functioning
+2-A2 +2-A2 +2-A2 correctly.
.K1 .K2 .K5
L+ NA_ZW
Inputs ID10 and ID11 must be
+2-A2. +2-A2.
not energized if both relay
+6-S1 Ign switch
QD QD P2 P6 L+C2 +2-A2
.K6
coils of K5 and K6 are not
NOT- NOT+ L+NA
switched on.
K5 is now switched on and
+2-A2.
+9-S10 F4/F9/F10 ID10 is checked to establish
ASS left
UP1-7/UI1
whether 24V power is present
ID10 = K5 OK.
ID11
K6 is then switched on and
24V power must be present at
+9-S11
Controller 2 ID5
ASS Right +2-A2. +2-A2. ID 11 = K6 OK.
P4 P5
QD49 If one of the two relays is not
INH QD50 OK, controller C2 doesn’t
ID58 QD38 +2-A2.R9 +2-A2.R8 energize both outputs QD49
+2-A2.P1
and QD50, also path L+NA has
no power.
+2-A2
.K10 The 24V INH input at C2 drops
+2-A2.R10
if one of the Emergency Stop
+1K12 buttons is pressed.
+2-A2 Engine fuel shut When the INH (inhibit) input is
.K10
+2-A2. off solenoid +2-A2 +2-A2 +2-A2 +2-A2 not energized, the controller
P3 24V= Fuel supply .K6 .K5 .K2 .K1 switch's all power outputs at
on
the controller off. Actuation of
the Emergency Stop relays is
T31 also not energized as a result.
Release ECM Release E-Stop Release C2 BMS

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 4.10.1 Machine Components – Electrics, Emergency Stop

+7-F10 3_ 80A
B+

Main control +2-A2.F3 1 P1 Ignition On

QD5
+2-A2 +2-A2 +2-A2
ID 5 at C2 = 24V
.K1 .K2 .K5
2 Relay +2-A2.K1 = 24V
L+ NA_ZW
+2-A2. +2-A2.
Relay +2-A2.K2 = 24V
+2-A2 +6-S1
QD QD P2 P6 L+C2
.K6
NOT- NOT+ L+NA
K1 picks up, supplying
+2-A2. P2
F4/F9/F10 L+ (key on)
+9-S10
ASS left 3
UP1-7/UI1 K2 picks up, supplying
ID10 P6
L+C2 (controller 2)
ID11
+9-S11
ASS Right
Controller 2 ID5 +2-A2. +2-A2.
If Emergency Stop
QD49
P4 P5 P3
button is not actuated
INH QD50 - 24V at INH/C2
ID58 QD38 +2-A2.R9 +2-A2.R8 4 - 24V at +2-A2.K10
+2-A2.P1

- Ground at ID58/C2
+2-A2
.K10
+2-A2.R10
+2-A2.K10 contact to
+1K12 5 +1K12, but no power
+2-A2 Engine fuel shut
.K10 supply
+2-A2. off solenoid +2-A2 +2-A2 +2-A2 +2-A2
P3 24V= Fuel supply .K6 .K5 .K2 .K1
on

T31
Release ECM Release E-Stop Release C2 BMS

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 4.10.2 Machine Components – Electrics, Emergency Stop

+7-F10 3_ 80A
B+

Main control +2-A2.F3 C2 verify zero voltage

QD5 6 at ID10 and ID11
+2-A2 +2-A2 +2-A2
.K1 .K2 .K5
L+ NA_ZW
When ID10 and ID11 at
C2 have zero voltage,
+2-A2. +2-A2.
+2-A2 +6-S1 P4
QD QD P2 P6 L+C2
.K6 QD49/C2 send an
NOT- NOT+ output and +2-A2.K5
7
L+NA
picks up.
+2-A2.
+9-S10 F4/F9/F10 ID10 = 24V
ASS left
UP1-7/UI1 ID11 = 0V
ID10
ID11
+9-S11
Controller 2 ID5 When step 7 was
ASS Right +2-A2. +2-A2.
P4 P5 P5 successful, QD50/C2
QD49 energizes +2-A2.K6.
INH QD50 8 ID10 = 24V
ID58 QD38 +2-A2.R9 +2-A2.R8
+2-A2.P1 ID11 = 24V

+2-A2
.K10
+2-A2.R10
If step 7 and 8
+1K12 successful, QD38/C2
9 send 24V to +1K12
+2-A2 Engine fuel shut
.K10
+2-A2. off solenoid +2-A2 +2-A2 +2-A2 +2-A2 Fuel supply solenoid
P3 24V= Fuel supply .K6 .K5 .K2 .K1
on

T31
Release ECM Release E-Stop Release C2 BMS

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 4.11 Machine Components – Electrics, Sensor Amplifier +2 –T5

Sensor amplifier +2-T5 amplifies the sensor signals of the speed initiators
for the traction drive system so that they can be read by the controller.
The amplifier is directly connected to the central PC board. The voltage
and the frequency can be measured at the plug +2A2.X39s if supervision
module is not connected.

a 24V power supply from F5

b Ground

1 Input from speed initiator sensor 1 LH Pin 3

2 Input from speed initiator sensor 1 LH Pin 4

3 Input from speed initiator sensor 1 RH Pin 4

2 4
a 1 3 4 Input from speed initiator sensor 1 RH Pin 3

Output to IC60/C2 and supervision module

5
6 Output to IC61/C2 and supervision module

7 Output to IC62/C2 and supervision module

8 Output to IC63/C2 and supervision module

From speed initiator 1 m/min VAC 37 Hz

b 5 7 From speed initiator 18 m/min VAC Hz
6 8
To controller 1 m/min VAC 37 Hz
To controller 18 m/min VAC Hz

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 4.12 Machine Components – Electrics, Box for Screed heating, Voltage Reglator

RH fuse +5-F42_16A

LH fuse +5-F40_16A Main contactor +5-K4

Voltage regulator MaccAlte

+5-T1
Below Rh side Operator Seat

Monitoring fuse +5-F39_32A

ISO- Insulation monitor

+5-B5

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 4.12.1 Machine Components – Electrics, Voltage Regulator +5-T1

Slow blow fuse 5A

CAN bus connection

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 4.12.2 Machine Components – Electrics, Voltage Regulator +5-T1

• Voltage regulator keeps the output voltage at a constant level of 400 VAC between
the phases, and 230 VAC between the phase and neutral conductors.
• Supply voltage for the voltage regulator is tapped from the three-phase supply of
the generator which is directly connected to the machine via the CAN bus.
• Excitation winding is connected via +F2 & -F1. The excitation current and excitation
voltage depend on the generator speed and current drawn (system load) and is
limited to 5A by the slow blow fuse.
• The voltage regulator is fed via the A1 & A2.
• The actual generator voltage is tapped between U2&N2.

Input to L1
Insulation N
monitor PE

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 4.12.3 Machine Components – Electrics, Insulation monitoring

• The insulation measuring instrument monitors the entire 400V system. The system is
designed as an IT protective system (insulated earth), which means that the machine chassis
is not electrically connected to the neutral conductor / phase conductor at any point.

• In the event of short-circuiting between phase or neutral to machine chassis, the later would
no longer be potential-free.

• This fault is detected immediately through use of the insulation monitor.

• The insulation monitor is a display unit only; screed heating is not switched off in the event
of a fault.

• The actual insulation resistance is indicated on the LC display. The alarm output is activated
when the resistance drops below 20kΩ. The values are preset and protected by a password
to prevent unauthorized change.

Power LED
Flashes if there is a break in
lines E,KE;L1,L2
F21 L1 Connects the monitored line L1
ON AL1 AL2
L2 Connects the monitored line N
A1 Supply voltage L1
A2 Supply voltage N
E PE connection
Alarm LED "AL2"
Lights up when resistance KE PE connection
drops below 20kΩ.
Flashes if there is a break 21 Input alarm relay K2
T R MENU
in lines E,KE;L1,L2 24 Output alarm relay K2

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 4.12.4 Machine Components – Electrics, Main Circuit Breaker +5-F39

Main circuit breaker will trip by high current (32A) and protect the cables and components

Auxiliary contact to get

error message

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 4.12.5 Machine Components – Electrics, Power contactor +5-K4

Power contactor makes and breaks the power circuit based on the C2 out put
QD56, depends on Screed heat ON/OFF

T31

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 4.12.6 Machine Components – Electrics, Circuit Breaker +5-F40 & +5-F42

Circuit breaker will trip by high current (16A) and protect the cables and components

Auxiliary contact to get

error message

auxiliary
contact
to get error
message
Screed heating LH Side Screed heating RH Side

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 4.13 Machine Components – Electrics, Generator ( MeccAlte)

• Make- MeccAlte
• Type- ECP 28-2L4 A , Synchronous
• 3 phase, AC Generator, Brushless
• Power 18 kw
• Housing dia 308mm
• Belt driven
• Heating ON / OFF Type
• Rotation of direction- Clockwise (view from shaft end)
• Gear Ratio 1/0.865 (1.15)
• Air cooled

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 4.13.1 Machine Components – Electrics, Generator- Principle

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 4.13.2 Machine Components – Electrics, Generator ( Mecc Alte)

Excitation Voltage Details

Checked in between –F1 & +F2

Engine running- High Idle, Screed heat OFF Engine running- High Idle, Screed heat ON
Excitation Voltage= 6.1 V dc Excitation Voltage= 9.06 V dc

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 Machine Components – Contrl System

Summary of chapter

5.0. Control system

5.1. Basics
5.2 CAN 0
5.3 CAN 1
5.4 CAN 3
5.5 CAN 4
5.6 CAN 5
5.8. Inputs and outputs
5.9. Input and output symbols

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 5.1 Machine Components – Contrl System Basics

120Ω

Supervision Controller 2
module

VDC VDC
120Ω

Parallel connection of the two 120 Ω terminating resistors yields a total resistance of 60 Ω. Resistance must be measured with
the ignition switched off!
Voltage value for CAN High and CAN Low with body earth can be determined with the ignition switched on. CAN High to body
earth ≈ 3.0VDC; CAN Low to body earth ≈ 2.0VDC

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 5.2 Machine Components – Contrl System, CAN 0

CAN 0

+3-A1 Main controller

& TR120Ω

+7-K2 Controller 2

Indevidual
Option

120Ω +2-A2.R21

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 5.3 Machine Components – Contrl System, CAN 1_LH side

+9-B29 +9-B27

Controller 2

+9-A5
120Ω

+7-R1

+2-A2.R24
120 ohm
+9-A3

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 5.4 Machine Components – Contrl System, CAN 3

+2-A2.R25
120Ω
120Ω

Controller 2 +7-R2

+2-A2 X23S

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 5.5 Machine Components – Contrl System, CAN 4_RH side

+9-B30 +9-B28 +9-A6

Controller 2
120Ω

+9-A4

+7-R3

120Ω
+2-A2.R26

Voltage
Stop module
Regulator
+5-T1.X3

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 5.6 Machine Components – Contrl System, CAN 5

120Ω

WITOS

WIDIAG

120Ω

+2-A2.R27

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 5.7 Machine Components – Control System, Inputs and Outputs- Example

PIN on connector Functional description

Location on the paver Graphical symbol

Type of device and Input or output

consecutive number Type of output or input

Connector on the
device Device name
Page number of the
Summary
PIN on connector

Inputs and outputs on controllers and CAN nodes

The boxes illustrated above represent an input or output on a CAN bus user.
These boxes contain the information needed to locate and check the relevant input / output on the
machine.
Each box consequently states the location (+7) on the paver, the type of device (-K2) and the device
connector (X1). The same information is also printed on the controller cables. The signal can be traced
precisely with the aid of the PIN number (23) on the connector.
The mode of operation of the signal can be determined precisely via the functional description, graphical
symbol and type of input or output (ID5 & QD5).

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 5.8 Machine Components – Control System, Input and Output Symbols

Symbol Significance Device code letter Significance Remarks

Voltage supply UI Ignition
UP Power supply
UB Continuous voltage supply
US General supply
UR Analog supply 5V reference voltage
UL Logic supply
Ground GND Ground
AGND Analog Ground
Inhibit Input unrelated to the microcontroller for central 24V = All outputs activated
enable/disconnection of power stages
CAN bus line CAN_H High bus line
CAN_L Low bus line
Digital input ID Input Digital 24V = 1 switched
0V = 0 not switched
Counter input IC Input Counter Frequency signal input from speed
sensors (traction drive system)
Voltage input IU Input Voltage PIN 19, 20 = 0V…32V
PIN 39,66,64,41,31,17,26 = 0V…10V
Current input II Input Current 0mA…20mA

Resistor input IR Input Resistor Evaluation of PTC temperature

sensors 700Ω…2000Ω

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 5.8.1 Machine Components – Control System, Input and Output Symbols

Symbol Significance Device code letter Significance Remarsk

Digital output QD Output Digital 24V = 1 switched
0V = 0 not switched
Voltage output QU Output Voltage Joystick outputs on the paver
operator's console
Counter output QP Output Pulse Output of the pave speed
potentiometer
Pulse width QPWM Output Pulse-Width-Modulation Variable current signal
modulation output up to max. 2.0A

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 Settings and measured values

6.0. Settings and measured values

6.1. Speed
6.2. Control system
6.3 Hydraulic system

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 6.1 Settings and measured values

Need to be checked with a paver

Travel speeds Travel drive system (examples)
Travel mode 4,5 km/h Speed Control pressure Current, pump Current, motor Frequency,
for traction for traction speed sensor
Travel mode Emergency - Manual 2,3 km/h
1 m/min 4,5 bar 234 mA 167 mA 37 Hz
Positioning mode 24 m/min 5 m/min 6,7 bar 285 mA 167 mA 173 Hz

Positioning mode Emergency - Manual 18 m/min 10 m/min 9,1 bar 348 mA 165 mA 340 Hz

Pave mode 24 m/min 24 m/min 14,7 bar 530 mA 200´mA 820 Hz

2 km/h 16,9 bar 610 mA 270 mA 1150 Hz

Pave mode Emergency - Manual 24 m/min
4,5 km/h 18,9 bar 670 mA 490 mA 2560 Hz

Engine speeds The travel motor begins its return oscillation at approx. 21m/min or 1.3km/h
Control pressure Current motor
MIN engine speed 900 1/min
Current Pump Frequency, speed sensor
ECO engine speed 1700 1/min
MAX engine speed 2000 1/min
Engine speed, screed heating 1350 1/min
Engine speed, hydraulic ram functions 1500 1/min

Material handling
Control current pump actuation, auger 200mA – 560mA
auger speed max. 85 1/min
Control current pump actuation, conveyor 200mA – 560mA
conveyor speed max. 65 1/min 1 m/min 5 m/min 10 m/min 24 m/min 2 km/h 4,5 km/h

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 6.2 Settings and measured values – Control system

Need to be checked with a paver

Tamper
Control current valve actuation 40L/80L 235 mA – 450 mA
Min. speed 450 rpm
Max. speed 1700-1800 rpm

Vibration (only on L version)

Control current valve actuation 500 mA – 595 mA
Min. speed, extending screeds 800 rpm
Max. speed, extending screeds 3000-3200 rpm

Potentiometer for steering IU37 on Controller 2

Left 0.7 V
Middle 2.3 V
Right 4.1 V

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 6.3 Settings and measured values – Hydraulic System

Travel drive system Valve block HA1 & HA2

Feed pressure 25 bar Pressure booster valve 0 / 180 bar
Control pressure ???bar Raise screed 180 bar
High pressure 445 bar Lower / freeze screed 15 bar
Pressure limitation (max. pressure regulation) 415 bar Raise hopper sides 180 bar
Lower hopper sides 15 bar
Augers
Levelling cylinders relief 70 bar
Feed pressure 25 bar
High pressure (LS) 230 bar Others

Pressure limitation 260 bar Tow point operation 50 bar

Volume per screed tow point ram 4 L/min
Conveyors Parking brake 40 bar
High pressure 200 bar Steering (High pressure relief) 200 bar
Steering LS 140 bar
Tamper & Vibration
Front wheel assist 200 bar
Pressure limitation 200 bar

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 Assisted starting / Welding

Summary of chapter

7.0. Assisted starting / welding

7.1. Jump starting

7.2. Welding

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 7.1 Assisted starting / Welding- Jump starting

Jump leads:
Caution! Check the polarity and voltage with the Multimeter
The correct sequence must be ensured when
on the dispenser vehicle and on the receiver vehicle.
connecting (orange) the leads. Disconnecting
in the reverse order.
Connect the red terminals to the positive poles, starting with
the faulty vehicle. Caution! Do not touch any moving engine
parts (e.g. V-belt, fan blades, electric generator)!

Connect the black lead to the negative pole of the donor

battery first. Then connect the other end to the engine block
or to a solid metal part connected to the engine block of the
faulty vehicle.
(On no account should it be connected directly to the
negative pole
of the weak battery, otherwise detonating gas may be ignited
when
the contact is made/broken).

Start the donor vehicle and let it run.

Now attempt to start the faulty vehicle.
When it has successfully been started, let the engine run for
several minutes.
Now switch on several powerful consumers in the faulty
vehicle: working lights, etc. to protect the electronics against
voltage surges.

The donor vehicle can then be switched off. If the engine of

Caution: Do not touch the terminals, as high currents flow the faulty vehicle cuts out, the dynamo / voltage regulator is
through the cable. The hydrogen formed due to the flow of not supplying sufficient power.
current may ignite if the cable is handled incorrectly
(explosion hazard).

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 7.2 Assisted starting / Welding- Welding

If welding is required on the paver or screed, the following

precautions must be taken without fail in order to prevent
the machine's electronic components being
damaged by over voltage or voltage peaks!
• Disconnect the paver operator's console from the on-
board supply.
• Unplug connectors X1 and X2 from controller 2
Paver operator's Controller 2 Screed consoles
console
• Unplug the two screed consoles.
• Disconnect the voltage regulator.
• Disconnect D+ of the alternator.
• Disconnect the earth terminal from the batteries.
• Directly connect the earth terminal of the welding
machine to the part to be welded.
Voltage regulator Batteries • Do not connect through rotating components (bearings).
• Do not route the welding cables parallel to electrical
cables.
The same precautions must also be taken during plasma
welding and plasma cutting!

D+ alternator

Use of a "welding surge protection" is

NOT sufficient!

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 Diesel Engine

Summary of chapter

8.0. Diesel engine

8.1. Info page engine

8.2.

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 List of lubricants
Super 1400
No Lubricant Type Refill Capacity Remarks Change Period

1 Diesel HSD 222 Liter - As Reqd

1st 50 hrs then

2 Engine Oil 15W40 14 Liter API-CI4 Plus
Every 250 hrs

3 Engine Coolant Compleat TM EG 24 Liter Premixed 50/50 Every 2000 Hrs

4 Hydraulic Oil Shell Tell us S2 V46 245 Liter HVLP ISO VG46 Every 1000 Hrs

Shell SPIRAX 1.5 Liter/ 1st 50 hrs then

5 Conveyor Gear box API GL-5-
S2 A90 Each side Every 1000 hrs

Shell SPIRAX 1.5 Liter/ 1st 50 hrs then

6 Auger Gear box API GL-5
S2 A90 Each side Every 1000 hrs

Advance drive Gear Shell SPIRAX 3.5 Liter / 1st 50 hrs then
7 API GL-5
Box S2 A90 Each side Every 1000 hrs

Shell SPIRAX 1st 50 hrs then

8 Splitter Gear box 9 Liter API GL-5
S2 A90 Every 1000 hrs

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