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Related Manuals for MBW CG200
Summarization of Contents
Forward and Process Awareness
Understanding the Slipforming Process
Explains the importance of knowledge and proper execution for paver results.
Paver Purchase Considerations
Key Variables for Paver Performance
Lists critical variables like grade, mix, slump, stringline, operator skill, and finishers.
Safety Precautions
Lethal Exhaust Gas Warning
Warns about carbon monoxide from engines and the need for ventilation.
Dangerous Fuels Warning
Advises caution with volatile fuels and no smoking during refueling.
Safety Guards and Electrical Shocks
Emphasizes keeping guards in place and warns about electrical shocks from ignition systems.
Personal Protective Equipment (PPE)
Lists required PPE like hearing, foot, head, and eye protection.
Introduction to the Manual
Manual Purpose and Operation Guide
Explains the manual's purpose to guide assembly and operation for safety and damage prevention.
Measurements and Paver Orientation
Details units of measure and paver orientation (front, rear, left, right).
Warranty and Machine Identification
Advises recording serial numbers for service and using genuine parts.
Safety Notice and Decal Information
Safety Alert Symbol Importance
Explains the "SAFETY ALERT SYMBOL" and its usage.
Reading and Maintaining Safety Decals
Stresses the importance of reading and maintaining safety decals.
Key Operating Safety Instructions
Provides key operating safety points like keeping others away and shutting off the engine.
Safety Decal Locations
Control Panel and Engine Compartment Decals
Lists specific decals found on the control panel and within the engine compartment.
Main Unit Engine Access Panel Decals
Identifies decals on the main unit's engine access panel.
Additional Safety Decal Locations
Fuel-Hydraulic Tank Decals
Lists decals on the fuel and hydraulic tank.
Side Drive Unit and Hopper Decals
Identifies decals on the side drive unit and hopper.
Front Fender Decals
Details decals on the front fender.
Warranty Information
Warranty Terms and Conditions
Outlines MBW Inc.'s warranty policy, exclusions, and procedures for claims.
MBW Warehouse Locations
Sales Branch Information
Provides contact details and locations for MBW Inc. sales branches in the US and UK.
Specifications
Machine Specifications
Lists technical details like weight, length, width, height, and capacity for different paver models.
Engine Specifications
Details engine type, power rating, and fuel type used in the paver.
Serial Numbers Identification
Main Unit Serial Number Location
Shows where to find the serial number for the paver's main unit.
Side Unit Serial Number Location
Indicates the location of the serial number for the side drive unit.
Engine Serial Number Location
Points out the location of the engine's serial number.
Control Panel Description
Safety Alert Symbol Explanation
Explains the "SAFETY ALERT SYMBOL" and the importance of reading safety signs.
Control Panel Item Functions
Lists and describes the function of each control on the paver's panel.
Control Panel Overview
Operator Controls Display
Visually displays the control panel with labels for various switches, meters, and indicators.
Vibrator Controls
Vibrator Speed Adjustment
Illustrates and labels the potentiometers for adjusting vibrator speeds for main and side units.
Operating Instructions
Pre-Operation Checks
Details essential checks before starting: safety, controls, fluids, battery, and hydraulics.
Starting the Engine
Engine Start-Up Procedure
Provides a step-by-step guide for starting the engine, including fuel valves, ignition, and preheat.
Stopping the Engine
Engine Shutdown Procedure
Outlines the correct steps to shut down the engine, including idling before stopping.
Assembly Instructions
C100 Paver Assembly Sections
Lists the sections included for the C100 model assembly.
C101 Paver Assembly Sections
Details the sections included for the C101 model assembly.
CG200 Paver Assembly Sections
Outlines the sections included for the CG200 model assembly.
Attaching Hopper Unit
Hopper Unit Mounting Procedure
Explains how to position, align, and secure the hopper unit to the main unit.
Side Drive Unit and Rear Drive Switch Settings
Details settings for the Side Drive Unit switch and Rear Drive switches.
Note on 12" Hopper Attachment
Highlights specific settings for the 12" hopper, including side drive and unused vibrators.
Attaching Molds
Mold Attachment for 12" Hopper
Describes how 12" molds bolt directly to the rear hopper face.
Mold Attachment for Larger Hoppers
Explains how larger molds slide into tracks on the side unit frame.
Mold Angle and Trim Bar Adjustment
Details adjusting the mold angle and trim bars for proper concrete flow.
Installing Vibrators
Vibrator Installation Overview & Hydraulic Ports
Explains factory-installed vibrators and hydraulic port locations.
Unused Vibrator Control Warning
Warns against dead-heading the hydraulic system by not switching off unused vibrator controls.
Changing Hoppers in the Side Unit
Hopper Removal and Installation
Provides steps for disconnecting, bracing, removing, and installing hopper units.
Installing Sensors
Front Steering & Height Sensor Installation
Details installing front sensors with sockets facing the front bracket.
Rear Steering Sensor Installation
Explains installing the rear steering sensor with the socket facing the rear bracket.
Rear Height Sensor Installation
Describes installing the rear height sensor with the socket facing the rear bracket.
Sensor Installation and Positioning
Front Steering Sensor Setup
Details positioning the front steering sensor and wand for stringline alignment.
Rear Steering Sensor Setup
Explains setting up the rear steering sensor, noting the sliding bracket for radius turns.
Sensor Shaft Handling and Usage Notes
Warns about fragile sensor shafts and limits on sensor usage.
Height Sensor Adjustments
Front and Rear Height Sensor Setup
Describes installing and positioning front and rear height sensors.
Wand Motion and Cable Connections
Instructs checking wand motion, connecting sensor plugs, and identifying cables.
Set-up and Pouring Instructions
Job Site Setup for Side Drive Unit (24+)
Details road bed grading and stringline setup for 24" and larger hoppers with side drive.
Machine Set-up Steps
Lists initial machine setup actions: start engine, turn power ON, check hydraulics.
Job Site Setup for Curb Only (12" Hopper)
Road Bed and Stringline for 12" Hopper
Explains grading and stringline setup specific to 12" hopper curb-only applications.
Machine Set-up for 12" Hopper
Lists initial machine setup steps for 12" hopper applications.
Automatic Sensor Set-up
Paver, Mold Positioning, and Leveling
Details initial positioning of the paver and mold relative to stringline and grade.
Steering Sensor Calibration (Front & Rear)
Guides calibration of front and rear steering sensors and wands for stringline tracking.
Automatic Steering Sensor Adjustments
Initial Control Switch Settings
Specifies initial switch positions for steering sensor adjustment.
Front Steering Sensor Zeroing and Adjustment
Explains how to check and zero the front steering sensor and adjust its potentiometer.
Steering Sensor Selector and Rear Calibration
Steering Sensor Selector Operation
Details using the selector switch for front/rear sensors and manual mode.
Front Steering Sensor Lamp Check and Adjustment
Explains interpreting indicator lamps and adjusting the front steering sensor.
Rear Steering Sensor Setup and Slide
Covers setting up the rear steering sensor and sliding it for tight radius turns.
Automatic Height Sensor Adjustments
Height Sensor Locations and Indicator Check
Identifies sensor locations for grading/pouring and checking indicator lamps.
Height Trim Potentiometer Adjustment
Details adjusting the Height Trim knob to turn off indicator lamps.
Adjusting the Height Limit Switch
Limit Switch Function and Installation
Explains the limit switch function and how to plug it in.
Limit Switch Adjustment and Testing
Details adjusting the switch position and testing it on a flat surface.
Fine-Tuning Limit Switch Height
Advises on fine-tuning the limit switch height for traction on different bases.
Grading with the Paver Before Pouring
Pre-Pouring Grade Control Setup
Outlines control switch settings for grading and initial paver movement.
Rear Machine Height and Stringline Check
Instructs setting rear height and checking stringline distance after grading.
Grade Cutting Blade Operational Warning
Warns that the blade removes high areas and identifies low areas, not for heavy soil.
Begin Pouring Procedures
Height Sensor Setting and Initial Pour
Ensures Height Sensor is set to POUR and details first pour steps.
Vibrator Settings and Engine Load
Advises adjusting vibrator settings based on concrete slump and engine load.
Main Manual Operator Functions During Pour
Lists the three key functions during pouring: vibrator speed, travel speed, and mold pitch.
Switching Steering Sensors
Straight Line Pouring with Front Sensor
Recommends using the front sensor for straight line pours.
Curve Transition with Sensor Switching
Details switching from front to manual, then to rear sensor for curves.
Front Sensor Wand Adjustment in Curves
Explains adjusting the front sensor wand as the paver approaches and leaves a curve.
Adjustments While Pouring
Manual Operator Adjustments During Pour
Lists adjusting vibrator speed, travel speed, and mold pitch during pouring.
Work Stoppage and Travel Speed Adjustments
Instructs turning off power for stops and adjusting travel speed.
Curb Height and Line Adjustments
Explains adjusting curb height with the trim knob and moving the curb line.
Adjustments After Pouring
End of Pour Procedures and Cleanup
Covers flipping auto power off, running out concrete, and raising the machine.
Machine Washing and Sensor Removal
Emphasizes cleaning concrete deposits and washing the mold; removing sensors.
Transport Speed Warning and Panel Cover
Warns about transport speed and recommends the control panel safety cover.
Operating Hints
Sensor Orientation and Mold Filling
Corrects sensor orientation and addresses issues with mold filling.
Curb Surface Quality and Mix Checks
Provides checks for unacceptable curb quality, including mix and vibrators.
Recommended Concrete Mix and Stringline Consistency
Details mix proportions and stresses stringline consistency for alignment.
Drive and Auto-Height Control Checks
Advises checking drive switches and Side Drive Unit switch for auto-height control.
Further Operating Hints
Rear Drive Switch Positions
Clarifies ON/OFF positions for rear drive switches with side drive unit or rear wheel.
Vibrator Settings and Engine Load
Relates vibrator pot settings to engine lugging and recommends turning off unused vibrators.
Grade Flatness and Uneven Grade Issues
Emphasizes grade flatness and explains issues from uneven grade.
Preventing Rear Wheel Lift and Hose Checks
Advises adjusting limit switch for wheel lift and checking hydraulic hoses.
Periodic Maintenance
Engine Oil Level Check Procedure
Details steps to check engine oil level, including cleaning, dipstick use, and adding oil.
Changing Engine Oil and Filter
Engine Oil and Filter Replacement
Provides steps for changing engine oil and filter, including safety and disposal advice.
Engine Air Filter Maintenance
Air Filter Cleaning and Replacement
Instructs on removing, cleaning/replacing, and seating the air filter element.
Fuel Filter Maintenance
Draining Water from Fuel Filter
Explains how to drain water from the fuel filter sediment bowl.
Fuel Filter Replacement Procedure
Details removing the old fuel filter and installing a new one, including priming.
Engine Coolant Level Check
Coolant Level Inspection
Details how to safely check the coolant level and the correct mixture.
Battery Maintenance
Battery Electrolyte Level Check
Provides safety warnings and steps for checking battery electrolyte levels.
Engine Fan Belt Check
Fan Belt Tension Adjustment
Explains how to check fan belt deflection and adjust tension.
Hydraulic Oil Level Check
Hydraulic Oil Level Inspection
Details checking the hydraulic oil level using the dipstick.
Changing Hydraulic Oil Filters
Hydraulic Filter Replacement Procedure
Outlines steps for turning off valves, removing, and installing hydraulic oil filters.
Changing Hydraulic Oil
Hydraulic Oil Replacement Procedure
Provides steps for draining, filling, and checking the hydraulic oil.
Maintenance and Lubrication Chart
Periodic Maintenance Schedule
Summarizes maintenance tasks, service frequency, and inspection standards.
Lubricant and Capacity Chart
Lists required lubricants, fluid types, and capacities for various components.
Troubleshooting Engine Problems
Engine Starting Problems
Lists symptoms like hard starting or stalling and corresponding potential problems.
Engine Performance Issues
Covers symptoms like knocking, power loss, and rough running with their causes.
Engine Warning Lamps and Smoke Symptoms
Addresses engine warning lamps and smoke issues with potential causes.
Fuel Consumption and Battery Issues
Details problems related to fuel consumption and battery charging.
Troubleshooting Engine System Issues
Fuel System Problems and Corrections
Lists fuel system issues like leaks, filter clogs, and injector problems with solutions.
Engine Oil and Cooling System Issues
Covers oil leaks, viscosity, filter clogs, and cooling system restrictions.
Electrical and Belt System Issues
Addresses battery, alternator, belt, and ignition switch problems.
Troubleshooting Paver Operation
Front Wheel Hunting and Steering Adjustment
Addresses front wheel "hunting" and how to reset the steering potentiometer.
Drive System and Auto-Height Control Issues
Covers machine not driving, drive switch issues, and auto-height control malfunctions.
Rear Wheel Lift and Mold Lowering Problems
Explains adjusting height trim and limit switches for rear wheel lift and mold lowering.
Vibrator Output and Travel Speed Issues
Suggests checking hydraulic pump suction hoses for kinks if output is low.
Hydraulic Schematic Diagram
Hydraulic System Overview
Presents the schematic diagram showing hydraulic components and flow.
Control Panel Wiring Diagram
Control Panel Circuitry
Displays the wiring diagram for the paver's control panel.
Machine Wiring Diagram
Overall Machine Electrical Connections
Shows the wiring diagram for the entire paver, including sensors and controls.
Mold Ordering
Mold Order Information Requirements
Lists necessary information for ordering a mold, emphasizing hopper opening dimensions.
Curb and Gutter Terminology
Defines terms related to curb and gutter profiles, including batter dimensions.
Terminology and Mold Features
Curb Terminology and Batter Requirements
Defines curb profile terms and the importance of batter for stability.
Sidewalk Terminology and Features
Defines sidewalk profile terms and batter requirements.
Water Drainage and Rebar Location Options
Explains gutter slopes for water and options for rebar openings.
Pouring Conditions
On Grade vs. Below Grade Pouring
Differentiates pouring on the same surface versus a lower surface.
Drop Pour Adapter Requirements and Types
Details the need for drop pour adapters when pouring below grade and adapter types.
MBW Inc. Mold Order Form
Mold Order Form Details and Requirements
Lists fields required on the mold order form, including serial numbers and pouring conditions.
Hopper Opening Size for Mold Selection
Specifies using the hopper size chart and providing height/width for mold fit.
Rebar Location Options for Molds
Outlines options for modifying hoppers or ordering new ones for rebar.
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