C-650-F MANUAL DE OPERACION.pdf

C-650-F/S Owner/Operator's Manual

C-650-F/S CYLINDER FINISHER OPERATOR’S MANUAL MACHINE SERIAL NUMBER:__________________________ ENGINE SERIAL NUMBERS:__________________________

GOMACOCorporation Highways59&175 IdaGrove,IA 51445 Telephone: 712-364-3347 FAX: 712-364-3986

FormNo.C-650-F/S-0705GC PrintedinUSA Copyright2005GOMACO

C-650-F/S

Table of Contents TO THE CUSTOMER: ............................................................................................................ 1-4 GENERAL SAFETY STATEMENTS ...................................................................................... 1-5 CHAPTER I—SAFETY SECTION .......................................................................................... 1-6 CHAPTER II—CONTROLS AND GAUGES ........................................................................... 2-1 Section 01—Content of chapter ..................................................................................................................... 2-1 Section 02—Engine controls and gauges ...................................................................................................... 2-1 Section 03—Console controls and gauges .................................................................................................... 2-4 Section 04—Carriage controls ...................................................................................................................... 2-10 Section 05—Stringline sensor controls ......................................................................................................... 2-12 Section 06—Moving the machine ................................................................................................................. 2-14

CHAPTER III—ASSEMBLY ................................................................................................... 3-1 Section 01—Content of chapter ..................................................................................................................... 3-1 Section 02—Assemble the machine frame .................................................................................................... 3-1 Section 03—Install the optional Powered Transition Adjuster (PTA) .............................................................. 3-4 Section 04—Install the stationary jack mounts (standard or slipform mounts) ............................................... 3-6 Section 05—Install self- or power-widening jack rails (C-650-F only) ............................................................ 3-7 Section 06—Install the optional power-widening system (C-650-F only) ....................................................... 3-8 Section 07—Install the self- or power-widening jack mounts (C-650-F only) ................................................. 3-9 Section 08—Install the grade jacks and bogies ............................................................................................ 3-10 Section 09—Install the tracks. ....................................................................................................................... 3-11 Section 10—Install the carriage and console. .............................................................................................. 3-12 Section 11—Install the hose reel assembly .................................................................................................. 3-13 Section 12—Install the E-Stop system ......................................................................................................... 3-14 Section 13—Install the optional electric cord reel ......................................................................................... 3-15 Section 14—Install the hydraulic hoses ........................................................................................................ 3-16 Section undercarriage .......................................................................................................... 3-16 Section 15—Install 16—Check the drum rotation ................................................................................................................. 3-19 Section 17—Install the standard auger(s) and auger guard ......................................................................... 3-20 Section 18—Install the carriage drive chains ............................................................................................... 3-21 Section 19—Mount the sensors (C-650-S only) ........................................................................................... 3-21 Section 20—Install the slipforms (C-650-S only) .......................................................................................... 3-24 Section 21—Install the optional Spanit ......................................................................................................... 3-26 Section 22—Install the undercarriage shift stops ......................................................................................... 3-28 Section 23—Install the float pan(s) ............................................................................................................... 3-29 Section 24—Install the optional pan vibrator ................................................................................................ 3-30 Section 25—Install the optional adjustable auger ........................................................................................ 3-32 Section 26—Install the optional rotary vibrator ............................................................................................. 3-33 Section 27—Install the optional carriage weight ........................................................................................... 3-35 Section 28—Install the transport assembly .................................................................................................. 3-35

CHAPTER IV—SETUP AND OPERATION ............................................................................ 4-1 Section 01—Content of chapter ..................................................................................................................... 4-1 Section 02—Bogie running surfaces (C-650-F only) ...................................................................................... 4-1 Section 03—Adjusting the height of the drums .............................................................................................. 4-2 Section 04—Installing a drum kit ...................................................................................................... 4-3 Section 05—Rigging for lifting lowering and installing on forms or bogie rails .............................................................. 4-4 Section 06—Adjust the machine to the stringline (sensor equipped machines only) ..................................... 4-5 Section 07—Square the frame to the slab surface ......................................................................................... 4-6 Section 08—Square up the optional PTA ....................................................................................................... 4-7 Section 09—Square the ends of the carriage rails to the slab surface ........................................................... 4-9

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C-650-F/S Section 10—Stringline the carriage rails to the slab profile .......................................................................... 4-10 Section 11—Adjusting the drum(s) to final grade ......................................................................................... 4-12 Section 12—Setting up the optional adjustable augers ................................................................................ 4-15 Section 13—Setting up the optional rotary stinger vibrator .......................................................................... 4-15 Section 14—Setting up the optional pan vibrator ......................................................................................... 4-16 Section 15—Starting a pour ......................................................................................................................... 4-17 Section 16—Machine operation and finishing procedures ........................................................................... 4-18 Section 17—Finish troubleshooting .............................................................................................................. 4-21 Section 18—Estimating the rate of pour and concrete usage ...................................................................... 4-22

CHAPTER V—MAINTENANCE ............................................................................................. 5-1 Section 01—Content of chapter ..................................................................................................................... 5-1 Section 02—Fuels .......................................................................................................................................... 5-1 Section 03—Lubricants .................................................................................................................................. 5-1 Section 04—4 or 5 hour service ..................................................................................................................... 5-1 Section 05—10 hour or daily service .............................................................................................................. 5-2 Section 06—50 hour or weekly service .......................................................................................................... 5-7 Section 07—100 hour service ....................................................................................................................... 5-11 Section 08—250 hour service ....................................................................................................................... 5-11 Section 09—500 hour or annual service ...................................................................................................... 5-12 Section 10—Adjusting pressures ................................................................................................................. 5-13 Section 11—Setting the carriage shift delay cylinder (machines with double-drum and Vib-O-Pac 200 undercarriages only) ........................................................................................................................................ 5-20

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C-650-F/S ¶034-0001

TO THE CUSTOMER: ¶034-0002

Your new GOMACO C-650-F Finisher was carefully designed and manufactured to give years of dependable service. To keep it running efficiently, read the instructions in this manual thoroughly. It contains detailed descriptions and instructions for the efficient operation and maintenance of your C-650-F. Each section is clearly identified so you can easily find the information that you need. Read the Table of Contents to learn where each section is located. All instructions are recommended procedures only. ¶034-0003

Throughout this manual you will come across “Caution”, “Warning” or “Danger” statements which will be printed in bold type and preceded by the symbols shown below. Be certain to carefully read the message that follows to avoid the possibility of personal injury or machine damage. D

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DANGER!

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¶034-0005

A “DANGER” STATEMENT IS OF UTMOST IMPORTANCE AND SIGNALS SEVERE INJURY OR HIGH PROBABILITY OF DEATH TO THE USER IF PROPER PRECAUTIONS ARE NOT TAKEN. W

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WARNING!

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¶034-0007.5

A “WARNING” STATEMENT INDICATES A POTENTIAL HAZARD WHICH COULD RESULT IN SERIOUS PERSONAL INJURY. C

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CAUTION!

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¶034-0009.5

A “CAUTION” STATEMENT INDICATES A HAZARD THAT COULD RESULT IN MINOR INJURY, OR DAMAGE TO EQUIPMENT. ¶034-0010.5

Notice: You will come across “Notice” statements which will be printed like this paragraph. A “Notice” statement explains a precaution or procedure to be taken to prevent personal injury, property damage or an unsatisfactory finished product. ¶034-0011

Right hand and left hand sides of the machine are determined by facing the direction the C-650-F will travel during paving operations. The auger side of the C-650-F is referred to as the “front” and the float pan is located at the “rear”. ¶034-0013

Record your C-650-F serial numbers in the appropriate spaces provided on the title page. Your GOMACO dealer needs this information to give you prompt, efficient service when you order parts. It pays to rely on an authorized GOMACO Distributor for your service needs. For the location of the Distributor nearest you, contact GOMACO. ¶034-0014

NOTE: It is GOMACO’s policy to constantly strive to improve GOMACO products. The information, specifications, and illustrations in this publication are based on the information in effect at the time of approval for printing and publishing. GOMACO therefore reserves the right to make changes in design and improvements whenever it is believed the efficiency of the machine will be improved without incurring any obligation to incorporate such improvements in any machine which has been shipped or is in service. It is recommended that users contact an authorized GOMACO Distributor for latest revisions.

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C-650-F/S

¶034-0015

GENERAL SAFETY STATEMENTS ¶034-0016

The C-650-F should only be operated by responsible persons who have thoroughly read the operator’s manual and have been properly instructed to do so. Do not allow unnecessary persons on the machine. ¶034-0017

Be certain all shields and guards are kept in place. ¶034-0018

Use adequate lifting devices while assembling and positioning the C-650-F. ¶034-0019

Keep hands, feet and clothing free of moving parts. Do not wear loose fitting clothing or jewelry that can catch on controls or other parts of the machine. ¶034-0021

Be certain that the engine are shut off before performing service or maintenance on the C-650-F. ¶034-0022.5

Stop the drum(s) and shut the engine off before making any adjustments to the carriage. ¶034-0023

Use care and adequate blocking material when adjusting the height of the machine to prevent injury. ¶034-0024

Wear a hard hat, protective glasses and other protective equipment as required by job conditions. ¶034-0025

Report all needed repairs. ¶034-0026

Keep hands and feet away from the carriage rail and the drive bogie rails.

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C-650-F/S ¶034-0027

make sure a new label is installed on the replaced part. Contact your GOMACO dealer for new labels.

CHAPTER I—SAFETY SECTION

¶034-0034

HIGH PRESSURE WATER

¶034-0028

The safety section lists basic safety precautions. In addition, this section identifies the text and locations of warning labels used on the machine.

¶034-0035

High pressure water can cause personal injury. When using high pressure water for cleaning, wear a protective face shield, protective clothing and protective shoes. Wear eye protection at all times when cleaning the machine. Pressurized water could cause debris and/or water to be blown and result in personal injury. Do not aim the nozzle at any part of

¶034-0029

Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this equipment. DCAL-058 ENGLISH

the body. FLUID LEAKS

NOTICE

¶034-0036

WARNING! DO NOT OPERATE THIS EQUIPMENT

¶034-0037

UNTIL YOU HAVE READ AND THOROUGHLY UNDERSTAND THE OPERATORS MANUAL. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN INJURY OR DEATH.

DANGER!

Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. ¶034-0038

DO NOT ALTER OR MODIFY THIS PRODUCT OF THE MANUFACTURER. UNAUTHORIZED

If fluid is injected into your skin, it must be treated by a doctor familiar with this type of injury immediately.

MODIFICATION MAY RESULT IN SERIOUS

¶034-0039

WITHOUT THE EXPRESS WRITTEN CONSENT

INJURY OR DEATH.

Do not kink or strike high pressure lines. Do not install kinked or damaged lines, tubes or hoses.

DCAL-058

¶034-0029.1

Operating the machine with a defective emergency stop (E-Stop) system can cause severe injury or death. Check the operation of each emergency stop button every day before beginnning operation. Make certain that all emergency stop buttons are pulled out and that the check E-Stop light on the panel is out.

¶034-0040

Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. ¶034-0041

Inspect all lines, tubes and hoses carefully. Do not use your bare hands to check for leaks. Tighten all

Depress each emergency stop button, one at a time. Depressing any one emergency stop button should cause the check E-Stop light on the panel to illuminate and machine functions to stop. If the check E-Stop light does not illuminate and machine functions do not stop after depressing any emergency stop button, check the system for faults and correct before operating the machine.

connections securely. ¶034-0042

Check for the following: ¶034-0043

• End fittings damaged or leaking. ¶034-0044

• Outer covering chafed or cut and wire reinforcing exposed. ¶034-0045

• Outer covering ballooning locally.

¶034-0030

WARNING SIGNS AND DECALS

¶034-0046

• Evidence of kinking or crushing of the flexible part of the hose.

¶034-0031

There are several specific safety signs or decals on your machine. Please take the time to familiarize yourself with the safety signs.

¶034-0047

• End fittings displaced.

¶034-0032

¶034-0048

Make sure that you can read all safety signs. Clean or replace signs if you cannot read the words or see the pictures. When cleaning the labels use a cloth, water, and soap. Do not use solvents, gasoline, etc., to clean

BURN PREVENTION ¶034-0049

Do not touch any part of an operating engine. Allow the engine to cool before any repairs are performed on

safety signs. The use of solvents, gasoline, etc., could loosen the sign’s adhesive and cause the sign to fall off.

the engine. ¶034-0050

Do not touch any hydraulic tank, valve or hose when at operating temperature. Allow the hydraulic oil to cool before performing any service on the hydraulic circuits.

¶034-0033

You must replace a label if it is damaged, missing, or cannot be read. If a label is on a part that is replaced,

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C-650-F/S ¶034-0051

¶034-0075

Relieve all pressure in oil or fuel systems before any lines, fittings or related items are disconnected or removed. ¶034-0059

When starting from an external source (jump starting), always connect the positive (+) jumper cable to the POSITIVE (+) terminal of the battery of the engine to be started.

BATTERIES

¶034-0076

To prevent potential sparks from igniting combustible gases produced by some batteries, attach the negative (-) boost ground cable last, to the starter NEGATIVE (-) terminal (if equipped) or to the engine block.

¶034-0060

Battery electrolyte contains acid and can cause injury. Avoid contact with the skin and eyes. ¶034-0061

Wash hands after touching batteries and connectors. Use of gloves is recommended.

¶034-0077

Clean and tighten all electrical connections. Check daily for loose or frayed electrical wires. Have all

¶034-0062

Batteries give off flammable fumes which can explode. Do not smoke when observing the battery electrolyte levels.

loose or frayed electrical wires tightened, repaired or replaced before operating the machine.

¶034-0063

¶034-0078

CRUSHING OR CUTTING PREVENTION

¶034-0064 ¶034-0079

Always wear protective glasses when working with batteries.

Support equipment and attachments properly when working beneath them.

¶034-0065 ¶034-0080

FIRE OR EXPLOSION PREVENTION

Never attempt adjustments while the engine is running unless otherwise specified in this manual.

¶034-0066

All fuels, most lubricants and some coolant mixtures are flammable.

¶034-0081

Stay clear of all rotating and moving parts. Guards should be in place whenever maintenance is not being performed.

¶034-0067

Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and gasoline fumes is extremely explosive.

¶034-0082

Wear protective glasses when striking objects to avoid injury to your eyes.

¶034-0068

Do not smoke in areas where batteries are charged, or where flammable materials are stored.

¶034-0083

Chips or other debris can fly off objects when stuck. Make sure no one can be injured by flying debris before striking any object.

¶034-0069

Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized persons.

¶034-0087

PREPARING TO START THE MACHINE

¶034-0070

Store all oily rags or other flammable material in a protective container, in a safe place.

¶034-0088.5

Be sure that all protective guards and covers are installed before the machine is started. To help prevent accidents, work carefully around rotating parts.

¶034-0071

Do not weld or flame cut the frame, pipes or tubes that contain flammable fluids without prior authorization and instruction from GOMACO or a GOMACO authorized dealer. Do not weld on the machine with the battery connected. Disconnect the battery negative (-) ground cable to prevent damage to the electrical system and/or explosion.

¶034-0089

Inspect the machine for potential hazards. ¶034-0090

Make sure no one is working on, or close to the machine before starting or moving it.

¶034-0072

Remove all flammable materials such as fuel, oil and other debris before they accumulate on the engine or other components of the machine. ¶034-0073

Do not expose the engine or hydraulic components to flames if at all possible. ¶034-0074

Have a fire extinguisher available at all times and know how to use it. Inspect and have it serviced as recommended on its instruction plate.

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C-650-F/S

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C-650-F/S CHAPTER II—CONTROLS AND GAUGES ........................................................................... 2-1 Section 01—Content of chapter ..................................................................................................................... 2-1 Section 02—Engine controls and gauges ...................................................................................................... 2-1 Section 03—Console controls and gauges .................................................................................................... 2-4 Section 04—Carriage controls ...................................................................................................................... 2-10 Section 05—Stringline sensor controls ......................................................................................................... 2-12 Section 06—Moving the machine ................................................................................................................. 2-14

C-650-F/S

C-650-F/S Engine start switch: Turn the key to the “start” position to start the engine. After the engine starts, allow the switch to return to the “on” position. The “on” position supplies electrical power to the electronic controls and the electric fuel solenoid. The “off” position shuts off all electrical power to the electronic controls and shuts off power to the electrical fuel solenoid to stop the engine.

CHAPTER II—CONTROLS AND GAUGES Section 01—Content of chapter This chapter describes engine, hydraulic, and electrical controls. It also gives the basic operating procedures for the C-650. Read this chapter thoroughly to identify the controls and operations. Only qualified personnel should be allowed to operate the C-650. Pay particular attention to all safety statements.

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CAUTION!

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TO PREVENT DAMAGE TO THE TURBOCHARGER, RUN THE ENGINE AT LOW IDLE FOR 30 SECONDS BEFORE SHUTDOWN.

Section 02—Engine controls and gauges

016-0148A

Notice: To prevent damage to the engine, read and understand the engine manual before starting the engine. W

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WARNING!

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TO PREVENT SERIOUS INJURY OR DEATH, MAKE SURE EVERYONE IS AWAY FROM ALL MOVING PARTS BEFORE STARTING THE ENGINE. STAY CLEAR OF ALL MOVING PARTSWHEN THE ENGINE IS RUNNING. STOP THE ENGINE AND REMOVE THE MASTER DISCONNECT SWITCH KEY BEFORE PERFORMING ANY SERVICE WORK ON ANY MOVING PARTS UNLESS OTHERWISE INSTRUCTED IN THIS MANUAL. IF THE ENGINE IS EQUIPPED WITH AN ENGINE HEATER, DO NOT USE ETHER. C

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CAUTION!

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CONTINUOUS EXPOSURE TO ENGINE NOISE CAN CAUSE HEARING DAMAGE. DO NOT OPERATE MACHINE WITHOUT HEARING PROTECTION. 016-0054B

Throttle switch: Controls engine speed. the throttle switch to the “low” position to start Mo andve idle the engine. Mo ve the throttle switch to the “high” position increase engine speed and operate the machine. Release the throttle s witch to stop adjusting engine speed. Allo w the engine to warm up before moving the throttle switch to the “high” position. Notice: To prevent engine damage, do not increase engine speed above 1000 rpm until the engine oil pressure has increased. When the oil pressure has increased, pull the throttle knob completely out before paving (the top speed of the engine has been factory-set at 2150 rpm). W

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WARNING!

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IF THE ENGINE IS EQUIPPED WITH AN ENGINE HEATER, DO NOT USE AERESOL STARTING AIDS (SUCH AS ETHER).

Engine start switch and throttle

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C-650-F/S 079-0285B

is 30 psi (2.07 bar) at 2150 rpm. Consult the engine operator’s manual for additional instructions. Volt meter: Shows the electrical system voltage. During normal operation the volt meter should read 14 volts at 2150 rpm. Notice: If voltage drops below 12 volts slow electrical response may occur. Locate the cause of low voltage and correct. Tachometer and hour meter: Shows engine speed (in revolutions per minute (rpm)) and hours of operation. Normal operating speed is 2150 rpm (maximum throttle).

Engine heater or glow plug switch:If the engine is equipped with an engine heater, and the air temperature is below 16º C, place the engine star t switch in the “on” position and hold the engine heater switch in the “on” position for 15 seconds before starting the engine. If the engine does not start, hold the engine heater switch in the “on” position for an additional 10 seconds before attempting to start again. Place the engine heater switch in the “off” position after the engine starts.

016-0061

If the engine is equipped with glow plugs, place the engine start switch in the “on” position and hold the glow plug switch in the “on” position for 15 seconds before starting the engine. Notice: To prevent damage to the glow plugs, do not hold the glow plug switch in the “on” position for more than 60 seconds.

Master disconnect switch:Prevents the engine from being started during machine service. Place the key switch in the “off” position and remove the key to disconnect the ground side of the electrical system from the negative post of the battery and keep the engine from being started. Replace the key and place it in the “on” position to reconnect the ground side of the electrical system to the negative post of the battery and allow the engine to be started.

016-0054A

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CAUTION!

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TO PREVENT DAMAGE TO THE ELECTRICAL SYSTEM, ALWAYS DISCONNECT BOTH BATTERY CABLES BEFORE WELDING ON ANY PART OF THE MACHINE. Engine gauges

Engine water temperature gauge: Shows the temperature of the engine coolant. Normal operating temperature is approximately 190° to 200° F (88° to °

93 C),temperature depending rises on outside temperature. the water aboveair 220 ° F (104° C),Iflocate the cause and correct. Engine oil pressure gauge: Shows the engine oil pressure. Minimum operating pressure for the engine

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C-650-F/S 079-0105A

016-0059

Engine oil dipstick: Remove the dipstick to check the engine oil level. If the oil level is low, add more through the oil cap until the oil level is to the full level on the dipstick. Check the dipstick after adding oil. Do not overfill. Replace the dipstick and tighten the oil cap securely.

Air filter restriction indicator: Monitors the condition of the engine air filter. Replace the air filter when the “service when red” window turns red. After replacing the air filter, push in on the button on the bottom of the air filter restriction indicator to reset it.

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WARNING!

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CAUTION!

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TO PREVENT ENGINE DAMAGE, CHECK THE ENGINE OIL LEVEL BEFORE STARTING THE ENGINE.

TO PREVENT FIRES AND BURN INJURIES, SHUT OFF ENGINES AND ALLOW THEM TO COOL BEFORE REFUELINGTHE ENGINES. DO NOT SPILL FUEL WHILE REFUELING. IF FUEL IS SPILLED, WIPE UP BEFORE STARTING ENGINES. DO NOT OVERFILL FUEL TANKS (LEAVE ROOM IN THE TANK FOR THE FUEL TO EXPAND).

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WARNING!

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DO NOT REMOVE THE RADIATOR CAP UNLESS IT IS COOL TO THE TOUCH. BEFORE REMOVING THE CAP, PLACE A RAG OVER IT.SLOWLY TURN THE CAP TO THE FIRST STOP, THEN WAIT UNTIL ALL STEAM ESCAPES THROUGH THE OVERFLOW TUBE.

016-0053A

016-0058

Engine fuel filler: To reduce condensation in the fuel, keep both fuel tanks full of clean fuel (leave some room in the tank for the fuel to expand). Do not use fuel left over from the previous season. Radiator cap: When the engine is cold, remove the radiator cap to check or add to the coolant. Check the coolant every day before starting the engine. The coolant level should be no more than 1 inch (25 mm) below the bottom of the filler neck.

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C-650-F/S C

016-0057

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CAUTION!

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TO PREVENT ENGINE DAMAGE, CHECK THE ENGINE COOLANT LEVEL BEFORE STARTING THE ENGINE. 016-0060

Hydraulic oil level and temperature gauge: Shows the level and temperature of the hydraulic oil. The hydraulic oil should be half way up the gauge when the oil is cold. If the oil level is low, add oil until the level is halfway up the gauge. Use only the proper grade of hydraulic oil.

Hydraulic oil filler cap: Remove to check hydraulic oil level or add hydraulic oil. The oil should be about 2 inches (5 cm) below the top of the tank when the oil is cold. If the hydraulic oil level is low, add hydraulic oil (the correct type is listed in Chapter V—Maintenance) until the correct level is reached.

Notice: To prevent damage to hydraulic components, do not operate the machine when the oil level is below the gauge.

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CAUTION!

Normal operating temperature is 140˚ to 180˚ F (60˚ to 82˚ C), depending on the air temperature. If the hydraulic oil temperature rises above 195˚ F (90˚ C), locate the cause of the overheating and correct.

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TO PR EVENT DAMAGE TO THE HYDRAULIC SYSTEMS, CHECK THE HYDRAULIC FLUID BEFORE STARTING THE ENGINE.

Notice: Excessive oil temperature can cause serious damage to pumps, motors, and other hydraulic components.

016-0056

Over heated oil can be caused by excessive load on hydraulic circuits, a hot day, restricted air flow through the oil cooler, and/or by a hydraulic circuit that is constantly exceeding relief pressure. Overheating can be corrected by reducing the load on the hydraulic circuits, cleaning the hydraulic oil cooler fins, and/or reducing the load on circuits that are exceeding relief pressure.

Section 03—Console controls and gauges

Hydraulic filter pressure gauge:Shows the amount of pressure needed to force oil through the main hydraulic filter. When the hydraulic oil is cold, the gauge needle may be in the yellow or red zones. When the hydraulic oil is warm, the gauge needle should be in the green zone. The filter must be changed when the hydraulic oil is warm and the needle is in the yellow or red zones (oil begins to bypass the filter when the needle enters the yellow zone; the filter is totally bypassed when the needle enters the red zone).

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WARNING!

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A DEFECTIVE EMERGENCY STOP (E-STOP) SYSTEM MAY CAUSE SEVERE INJURY ORDEATH. DO NOT OPERATE ANY MACHINE WITH AN INOPERATIVE EMERGENCY STOP SYSTEM. CHECK THE EMERGENCY STOP SYSTEMEVERY DAY FOR PROPER WORKING OPERATION.

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C-650-F/S 008-0346A

W

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WARNING!

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TO PREVENT SERIOUS INJURY OR DEATH, BE CERTAIN THAT ALL CONTROLS ARE IN THE “OFF” OR “NEUTRAL” POSITION BEFORE RESETTING THE E-STOP SYSTEM. BE CERTAIN THAT EVERYONE IS CLEAR OF THE BOGIES, CARRIAGE, CARRIAGE CHAIN(S), AND CARRIAGE COMPONENTS BEFORE RESETTING THE EMERGENCY STOP SYSTEM. 008-0346B

Check Emergency Stop (E-Stop) light:Illuminates whenever the emergency stop (E-Stop) system is activated. The emergency stop system is activated whenever the key switch is turned from the “off” to the “on” positions, whenever any of the E-Stop buttons are pushed in, or whenever any of the E-Stop buttons are disconnected from the E-Stop system. When the E-Stop system is activated, the carriage and the machine stop moving and the drums, augers, and vibrators stop working. If the check E-Stop light comes on, immediately make sure all personnel are safe.

Emergency Stop (E-Stop) reset switch:Allows the machine to operate after the emergency stop system has been activated. The emergency stop reset switch must be pushed up to the “reset” position whenever the engine is started or any emergency stop button pushed in or disconnected.

098-0045

When the check emergency stop light comes on, place all controls in the “neutral” sure all personnel are safe.or “off” position and make To resume operation, make sure all emergency stop buttons are connected to the machine and pulled out. Place all controls in the “neutral” or “off” position. Push the emergency stop reset switch up to reset the emergency stop system. The check emergency stop light will go out, and the machine will operate normally. 016-0041A

Emergency Stop (E-Stop) buttons:If any E-Stop button is pushed in or disconnected, the E-Stop system is activated. When the E-Stop system is activated, the E-Stop light comes on, the machine and carriage stop moving, and the drums, augers, and vibrators also stop working. All E-Stop buttons must be pulled out during normal operation. If an E-Stop button has been pushed in and the check E-Stop light comes on, immediately make sure all personnel are safe.

Left and right advance valves

Left advance valve:Allows the left side of the machine to move ahead of the right side. If the handle is turned counterclockwise, oil for the right drive bogie

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C-650-F/S 016-0063A

or track is bypassed back to tank, and the right bogie or track slows down or stops. As the left drive bogie or track advances at normal speed, the left side of the machine moves ahead of the right, turning the machine to the right. The rate of left-side advance is controlled by how far the left advance and variable travel valves are turned. If the left and right advance control handles are turned completely clockwise, both sides of the machine will travel at the same speed and the machine will move straight ahead. Right advance valve: Allows the right side of the machine to move ahead of the left side. If the handle is turned counterclockwise, oil for the left drive bogie or track is bypassed back to tank, and the bogie or track slows down or stops. As the right drive bogie or track advances at normal speed, the right side of the machine moves ahead of the left, turning the machine to the left.

Travel speed valve: Controls the machine travel speed when the travel direction control valve is in “forward” or “reverse.” The machine should always be started or stopped with this valve. When the travel speed valve is on the “0” position, the machine will not move. As the valve is rotated clockwise (towards higher numbers) the machine will begin to move (provided the advance control valves are turned completely clockwise and the travel directional valve is in the “forward” or “reverse” position). The more the valve is turned clockwise (towards higher numbers), the faster the machine will move.

The rate of right-side advance is controlled by how far the right advance control and variable travel valves are turned. If the left and right advance control handles are turned completely clockwise, both sides of the machine will travel at the same speed and the machine will move straight ahead. 016-0072A

Turn the black knob on the valve lever clockwise to lock the valve in any position. 016-0062C

Travel direction valve: Controls the direction of machine travel. When the valve is placed in the “forward” position, the machine will move forward. When the valve is placed in the “reverse” position, the machine will move backwards. When the control valve is placed in the “neutral” position, the machine will not move.

Travel/vibrator on/off switch (optional):Stops and starts machine travel and optional console vibrators. Place the travel/vibrator on/off switch in the “on” position to move the machine and run the optional console vibrators. Place the travel/vibrator on/off switch in the “off” position to stop machine travel and the optional console vibrators.

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C-650-F/S W

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WARNING!

main relief will open and the system pressure gauge will read 2350 psi (161.9 bar).

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Lift Pressure Gauge (optional): Monitors the amount of hydraulic pressure available for the optional automatic grade control system. Normal lift pressure is 1600 psi (105 bar).

TO PREVENT PERSONAL INJURY, USE THE CARRIAGE TRAVEL VALVE, NOT THE CARRIAGE TRAVEL VARIABLE VALVE (LOCATED ON THE CARRIAGE) TO START AND STOP CARRIAGE MOVEMENT.

Notice: If Lift Pressure Drops Below 1000 Psi (69 Bar), Machine Control May Become Slow. Locate the cause of low pressure and correct.

016-0064A

016-0062B

Carriage travel valve:Turns all carriage operations on or off. Place the carriage travel valve in the “on” position to start carriage operations. Place the carriage travel valve in the “off” position to stop all carriage operations. When the carriage travel valve is in the “off” position, the carriage will stop moving across the machine frame, the drum(s) and auger(s) will stop turning, and any vibrators attached to the carriage will stop operating.

Carriage vibrator on/off switch (optional):The vibrator on/off switch turns the optional pan or rotary stinger vibrator on or off. Place the switch in the “on” position to start vibrator operation. Place the switch in the “off” position to stop vibrator operation.

016-0050H

016-0062A

Pressure gauges

Carriage vibrator up/down switch (optional):The vibrator up/down switch raises and lowers the optional rotary stinger vibrator. Hold the switch in the “up” position to lift the stinger vibrator. Hold the switch in the “down” position to lower the stinger vibrator.

Carriage pressure gauge: Shows the pressure of the hydraulic oil going out to the carriage. The oil is used to move the carriage along the machine frame and operate the carriage functions (drum(s), augers, vibrators, Normal slump operating willof vary, dependingetc.). on concrete andpressure the amount concrete being pushed by the drums and augers. If the carriage is moving freely across the frame, the carriage pressure gauge will show counterbalance pressure (500 psi (34.5 bar). If the carriage stalls, the

2-7

C-650-F/S 016-0054C

and lowers the machine frame so the machine can finish crowns or inverts in the slab. Hold the transport axle or PTA valve in the “up” position to lift the transport wheels or increase the crown in the machine frame (depending on which quick couplers are connected). Hold the transport axle or PTA valve in the “down” position to lower the transport wheels or decrease the crown in the machine frame (depending on which quick couplers are connected). Release the transport axle or PTA valve to the “neutral” position to lock the transport wheels or machine frame crown in the desired position.

Console vibrator variable(s) (optional):Control the speed of the optional vibrator(s) connected to the console. Place a console vibrator variable on the “0” position to stop the vibrator in its circuit. Move a console vibrator variable to a higher number to begin operating the vibrator and to increase its speed. C

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CAUTION!

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TO PREVENT MACHINE DAMAGEWHEN THE MACHINE IS EQUIPPED WITH ONE OR MORE OPTIONAL VIBRATOR HYDRAULIC CIRCUITS, CONNECT THE VIBRATOR QUICK COUPLERS TOGETHER AND PLACE THE VIBRATOR VARIABLE CONTROL VALVE(S) IN THE “0” POSITION WHENEVER THE MACHINE IS USED WITH A

To change the height of the crown or the transport axle wheels when the machine is not moving, place the travel directional control valve in the “neutral” position, rotate the variable travel valve in the “increase” direction, and hold the transport axle or PTA valve in the “up” or “down” position. To change the height of the crown or the transport axle wheels while the machine is paving or backing up, hold the transport axle or PTA valve in the “up” or “down” position (the travel speed may decrease slightly while the PTA or the transport axle is being raised or lowered). 008-0373

VIBRATOR DISCONNECTED. 016-0072B

Transport jack needle valves

Transport jack needle valves: Regulate hydraulic flow to the lift cylinders in the transport axles. If one of the cylinders is going up or down faster than the other, turn the cylinder’s needle valve clockwise to slow the cylinder speed. When the cylinders have been completely raised or lowered, turn the needle valves completely clockwise to lock the cylinders in position.

Transport axle or PTA valve: Controls the transport axle lift cylinders and the power transition adjuster (the quick couplers from the transport axle or PTA must be connected to the transport axle or PTA valve quick couplers before either can be used).

Notice: to keep the transport wheels up when the transport axle quickturn couplers are disconnected from the machine, the transport jack needle valves completely clockwise before the transport axle quick couplers are disconnected.

The transport axle and wheels are lifted up out of the way during paving operations and lowered to the ground when the machine is moved. The PTA raises

2-8

C-650-F/S 047-0231A

047-0243B

Grade solenoid valve override buttons: Manually control the grade solenoid valves to raise or lower the legs for troubleshooting purposes. If sensor or jog switch will not raise or lower a leg, depress the corresponding button on either side of the solenoid valve for that leg. If the leg moves up or down, the problem is in the electric system. If the leg doesn’t move up or down, the problem is in the hydraulic system.

Steering needle valve:Controls the speed of the steering when the machine is being steered with the sensor or jog switch. Rotate the valve knob counterclockwise to increase steering speed. Rotate the valve knob clockwise to decrease steering speed.

Steering needle valve

016-0065

047-0243A

Typical pressure relief valve

Pressure relief valves: Set the maximum hydraulic pressure of a hydraulic circuit, relieving pumps from pressure spikes. If the pressure in a circuit is too high, the circuit’s pressure relief valve opens and bypasses hydraulic oil back to the reservoir. If one pressure relief valve opens in one circuit, it does not affect the operation of any other circuit (it will only dump the oil from the stalled circuit). See Chapter V— Maintenance to set the pressure relief valves.

Steering solenoid valve override buttons:Manually control the steering solenoid valves to steer the tracks for troubleshooting purposes. If sensor or jog switch will not steer the tracks, depress the button on the corresponding solenoid valve. If a track slows down and turns the machine, the problem is in the electric system. If a track doesn’t slow down, the problem is in the hydraulic system.

2-9

C-650-F/S 016-0066A

the emergency stop system and stop all machine operations whenever it is pushed in or disconnected (the drum(s), auger(s), vibrator, undercarriage rotation, bogies, and carriage drive will all stop). To resume operation if any emergency stop button pushed in or disconnected, first make sure all personnel are safe, then place all console and carriage controls in the “off” or “neutral” position. Make sure all emergency stop buttons are pulled out and connected and push the emergency stop reset switch up to the “reset” position to turn off the emergency stop reset light and resume machine operations. Circuit breaker

W

Circuit breaker: Two self-resetting circuit breakers are installed behind the control console to protect the electrical circuits. If there is a short in a breaker’s electrical circuit, the breaker will click on and off. Find the source of the short and repair.

Section 04—Carriage controls W

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WARNING!

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WARNING!

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TO PREVENT PERSONAL INJURY, DO NOT USE THE CARRIAGE VARIABLE TRAVEL SPEED CONTROL VALVE TO START AND STOP CARRIAGE MOVEMENT. ALWAYS USE THE CARRIAGE TRAVEL VALVE ON THE CONSOLE TO START AND STOP CARRIAGE MOVEMENT. 016-0067

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A DEFECTIVE EMERGENCY STOP (E-STOP) SYSTEM MAY CAUSE SEVERE INJURY OR DEATH. DO NOT OPERATE ANY MACHINE WITH AN INOPERATIVE EMERGENCY STOP SYSTEM. CHECK THE EMERGENCY STOP SYSTEM FOR PROPER WORKING ORDER BEFORE BEGINNING P AVING OR OPERA TIONS. PREVENT SERIOUS INJURY DEATH, BETO CERTAIN THAT ALL CONTROLS ARE IN THE “OFF” OR “NEUTRAL” POSITION BEFORE RESETTING THE EMERGENCY STOP SYSTEM. BE CERTAIN THAT ALL PERSONS ARE CLEAR OF THE BOGIES, CARRIAGE, AND CARRIAGE COMPONENTS BEFORE RESETTING THE EMERGENCY STOP SYSTEM. 008-0421

Carriage travel speed valve: Controls the speed of the carriage as it moves across the machine frame. When the carriage travel speed valve is placed the “0” position, the carriage will not move when the carriage travel valve on the console is placed in the “on” position. If the carriage variable travel speed control valve is placed on a number greater than “0” (towards the “increase” direction), the carriage will move across the frame when the carriage travel valve on the console is placed in the “on” position. The more the valve is moved in the “increase” direction (towards higher numbers), the faster the carriage will move when the carriage travel valve on the console is placed in the “on” position. Turn the black knob on the valve lever clockwise to lock the valve in any position.

Carriage Emergency Stop button (optional):The carriage emergency stop button(s) are connected to

2-10

C-650-F/S 016-0055

more the valve is moved clockwise, or towards higher numbers, the faster the vibrator will operate. Turn the black knob on the valve lever clockwise to lock the valve in any position. C

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CAUTION!

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TO PREVENT MACHINE DAMAGE WHEN THE MACHINE IS EQUIPPED WITH ONE OR MORE OPTIONAL VIBRATOR HYDRAULIC CIRCUITS, CONNECT THE VIBRATOR QUICK COUPLERS Vibrator remote (optional): The vibrator on/off switch turns the optional pan or rotary stinger vibrator on or off. Place the switch in the “on” position to start vibrator operation. Place the switch in the “off” position to stop vibrator operation.

TOGETHER, PLACE THE VIBRATOR CONTROL VAL VE(S) IN THE “0” POSITVARIABLE ION, AND PLACE THE VIBRATOR ON/OFF SWITCH (ON THE CONSOLE OR THE VIBRATOR REMOTE) IN THE “OFF” POSITION WHENEVER THE MACHINE IS USED WITH A VIBRATOR DISCONNECTED. 016-0069A

The vibrator up/down switch raises and lowers the optional rotary stinger vibrator. Hold the switch in the “up” position to lift the stinger vibrator. Hold the switch in the “down” position to lower the stinger vibrator. Release the switch to stop raising or lowering the vibrator. W

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WARNING!

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TO PREVENT PERSONAL INJURY, DO NOT USE THE VIBRATOR VARIABLE CONTROL VALVE TO START AND STOP VIBRATOR OPERATION. ALWAYS USE THE VIBRATOR ON/OFF SWITCH ON THE CONSOLE OR CARRIAGE TO START AND STOP VIBRATOR OPERATION. 016-0068

Solenoid valve overrides (optional):Manually control the operation of the optional vibrator on/off and rotary stinger vibrator lift solenoid valves. If the electric coil on a solenoid valve or the wiring to the coil fail, the solenoid valve overrides can be used to operate the vibrator or vibrator lift and to troubleshoot the problem. If an electric control does not operate a hydraulic circuit, but an override does, there is an electrical problem. If the override does not operate a hydraulic circuit, there is a hydraulic problem.

Vibrator variable speed valve(s): The vibrator variable speed control valve(s) control the speed of the vibrator(s). When a vibrator variable speed control valve is placed the “0” position, the vibrator in its circuit will not operate. If a vibrator variable speed control valve is placed on a number greater than “0” (rotated clockwise), the vibrator in its circuit will operate. The

2-11

C-650-F/S 008-0168A

Section 05—Stringline sensor controls Console electronic controls: 098-0063

Carriage shift control valve(s): Automatically shifts the carriage direction and drum angle of attack at each side of the pour. Also turns the optional rotary vibrator mount at the each side of the pour. 008-0418A

The electronic console controls for the grade and steering consist of on/off switches, jog switches, and indicator lights for the four track legs and the steering. All systems are identical. The following descriptions apply to all systems. On/off switches: Switch automatic control of the legs or steering system on or off. Place an on/off switch in the “off” position to turn off automatic control to a track leg or the steering (the sensor will not control the Pressure relief valves: Set the maximum hydraulic pressure of a hydraulic circuit, relieving pumps from pressure spikes. If the pressure in a circuit is too high, the circuit’s pressure relief valve opens and bypasses hydraulic oil back to the reservoir. If one pressure relief valve opens in one circuit, it does not affect the operation of any other circuit (it will only dump the oil from the stalled circuit). See Chapter V— Maintenance to set the pressure relief valves.

system). Place an on/off switch in the “on” position to turn on automatic control to a track leg or the steering (the sensor will control the system). Jog switches: Manually raise or lower each leg or steer the machine to the left or right. Hold a grade jog switch in the up ( ) or down ( ) position to raise or lower a track leg. Hold the steer jog switch in the left ( ) or right ( ) position to turn the machine to the left or right. Release a jog switch to the center position to stop raising or lowering a track leg or steering the machine to the left or right. Note: The machine must be moving forward or backward for the steering jog switch to work. The jog switches will raise or lower the legs or steer the tracks if the on/off switch is in either the “on” or “off” positions (if on/off switch is in the “on” position, the sensors will resume control as soon as the jog switches are released). Indicator lights: Light up whenever a sensor or a jog switch sends an up, down, right, or left signal. For example, if the right front grade sensor sends a down signal, the right front grade down light will light up; if

2-12

C-650-F/S the steering jog switch is moved to the left position, the left steering indicator light will light up. If a sensor sends a signal, the indicator lights will light up if the on/ off switch is in the “on” or the “off” position.

047-0009A

Sensor controls: The C-650 uses electronic stringline sensors to control machine grade and steering. For troubleshooting purposes, all sensors are identical. The following descriptions apply to all sensor systems. 079-0320

Indicator lights: The indicator lights on the sensors light up when the sensor wand moves up or down or right or left along the stringline. For example, if the stringline moves up, the grade wand moves up, and the up ( ) indicator light on the sensor comes on. The sensor indicator lights have the same function as the indicator lights on the console. 047-0009C

Grade and steering sensors:The grade and steering sensors automatically control the machine elevation (grade) and steering of the legs and tracks. Each of the sensors contains an on/off switch, a set of indicator lights, and a sensitivity screw. 047-0009B

Sensitivity screw: The sensitivity screw controls how far a sensor wand must move before the sensor sends a signal to operate the system. Turn the sensitivity screw clockwise to decrease sensitivity (the sensor wand must move farther before the sensor moves the legs up or down or turns the tracks right or left). Turn the sensitivity screw counterclockwise to increase sensitivity (the sensor wand won’t move as far before the sensor moves the legs up or down or turns the tracks right or left). On/off switch: The on/off switch on each sensor turns the sensor on and off. Place an on/off switch in the “off” position to manually operate the grade or steering system controlled by the sensor. Place an on/off switch in the “on” position to allow the sensor to automatically operate the grade or steering system. The sensor on/off switches have the same function as the on/off switches on the console.

Before operating the machine on a stringline for the first time, turn the sensitivity screws on all the sensors completely clockwise, then turn them counterclockwise one third of a turn. When the machine is on the stringline, check the grade and steer sensor operation. If the legs seem to be moving up and down too quickly, or the machine is turning to the right and left while it is moving along a straight stringline, turn the sensitivity screw clockwise on the sensor controlling the system just far enough to stop the grade or steering problem

2-13

C-650-F/S (the sensitivity screws should be turned counterclockwise as far as possible without making the legs or the steering unstable.

Section 06—Moving the machine Pre-Start Checks: Check all oil and coolant levels and perform all necessary maintenance the machine before starting engine. See Chapter IV— Maintenance for a complete listing of all maintenance procedures.

C

CAUTION!

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CONTINUOUS EXPOSURE TO ENGINE NOISE CAN CAUSE HEARING DAMAGE. DO NOT OPERATE MACHINE WITHOUT HEARING PROTECTION.

WARNING!

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Place the track directional valve in the “forward” or “reverse” position. To start moving the machine, slowly rotate the travel speed valve clockwise. To steer the machine, rotate the left or right advance valves, or place the steer on/off switch in the “on” position and move the “jog” switch on the steering control panel to the left ( ) or right ( ) position as needed.

W

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WARNING!

TO PREVENT SERIOUS INJURY OR DEATH BE CERTAIN THAT THE AREA AROUND THE MACHINE AND THE TRACKS IS CLEAR BEFORE MOVING OR TURNING THE MACHINE. MOVE SLOWLY WHILE LOADING OR UNLOADING THE MACHINE OR WHEN TRAVELING DOWN EMBANKMENTS. To move the C-650, increase the engine speed to maximum. Use the grade jacks or grade jog switches to raise the machine high enough to clear any obstacles.

Before starting the engine, place all controls in the neutral or “off” position. Place all sensor control switches in the “off” position.

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W

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TO PREVENT SERIOUS INJURYOR DEATH. MAKE SURE EVERYONE IS AWAY FROM THE MACHINE AND ALL MOVING PARTS BEFORE STARTING THE ENGINE. THE OPERATOR MUST REMAIN ON THE OPERATORS PLATFORM WHILE THE ENGINE I S RUNNING. PLACE ALL CONTROLSIN THE "OFF" OR "NEUTRAL" POSITION AND SHUT OFF THE ENGINE BEFORE DISMOUNTING THE MACHINE. Turn the ignition key to the “start” position until the engine starts. Release the key and allow it to return to the “on” position. After the engine starts, do not increase engine speed above 1000 rpm for one minute to allow engine oil pressure to increase. Increase the engine speed to 1500 rpm and allow the engine to warm-up for 3 to 5 minutes. If the air temperature is below 60º F (16º C), place the engine start switch in the “on” position and hold the engine heater or glow plug switch in the “on” position for 15 seconds before starting the engine (the engine heater light will come on when the engine heater switch is in the “on” position). If the engine does not start, place the engine switch in the “on” position for an additional 10 seconds before attempting to start again. Place the engine heater switch in the “off” position after the engine starts. Notice: Do not operate the starter longer than 30 seconds at a time or damage may result to the star ter. Allow the starter to coolfor 2 or 3 minutes between starting attempts.

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C-650-F/S CHAPTER III—ASSEMBLY ................................................................................................... 3-1 Section 01—Content of chapter ..................................................................................................................... 3-1 Section 02—Assemble the machine frame .................................................................................................... 3-1 Section 03—Install the optional Powered Transition Adjuster (PTA) .............................................................. 3-4 Section 04—Install the stationary jack mounts (standard or slipform mounts) ............................................... 3-6 Section 05—Install self- or power-widening jack rails (C-650-F only) ............................................................ 3-7 Section 06—Install the optional power-widening system (C-650-F only) ....................................................... 3-8 Section 07—Install the self- or power-widening jack mounts (C-650-F only) ................................................. 3-9 Section 08—Install the grade jacks and bogies ............................................................................................ 3-10 Section 09—Install the tracks. ....................................................................................................................... 3-11 Section 10—Install the carriage and console. .............................................................................................. 3-12 Section 11—Install the hose reel assembly .................................................................................................. 3-13 Section 12—Install the E-Stop system ......................................................................................................... 3-14 Section 13—Install the optional electric cord reel ......................................................................................... 3-15 Section 14—Install the hydraulic hoses ........................................................................................................ 3-16 Section 15—Install the undercarriage .......................................................................................................... 3-16 Section 16—Check drum rotation ................................................................................................................. 3-19 Section 17—Install the standard auger(s) and auger guard ......................................................................... 3-20 Section 18—Install the carriage drive chains ............................................................................................... 3-21 Section 19—Mount the sensors (C-650-S only) ........................................................................................... 3-21 Section 20—Install the slipforms (C-650-S only) .......................................................................................... 3-24 Section 21—Install the optional Spanit ......................................................................................................... 3-26 Section 22—Install the undercarriage shift stops ......................................................................................... 3-28 Section 23—Install the float pan(s) ............................................................................................................... 3-29 Section 24—Install the optional pan vibrator ................................................................................................ 3-30 Section 25—Install the optional adjustable auger ........................................................................................ 3-32 Section 26—Install the optional rotary vibrator ............................................................................................. 3-33 Section 27—Install the optional carriage weight ........................................................................................... 3-35 Section 28—Install the transport assembly .................................................................................................. 3-35

C-650-F/S

C-650-F/S super-elevation and on the opposite side of the crane or the concrete pump.

CHAPTER III—ASSEMBLY

4. PTA location: The optional PTA assembly may be installed between any of the standard pinconnected frame sections. Several PTA assemblies can also be installed. Plan to position PTA joints over the crown(s) or invert(s) in the slab. If the machine is not equipped with a PTA, but the slab will be poured with a crown or an invert, assemble the frame so that a pin-connect joint is above the crown or invert.

Section 01—Content of chapter This chapter contains instructions for the assembly of the C-650. Also covered are the instructions for mounting the attachments to the machine. All adjustments are recommended procedures only. Read this chapter thoroughly to identify yourself with your particular machine. Pay particular attention to all safety statements.

Assemble the main frame:The directions below describe frame assembly starting from the end of the machine opposite the console. Lay out all components—frame panels, jacks, and console—on the correct sides of the machine.

Section 02—Assemble the machine frame W

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WARNING!

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USE FINGERS TO CHECK ALIGNMENT OF BOLT HOLES. WHEN PARTS OR THE MACHINE SHIFTS YOUR FINGERS MAY BE AMPUTATED. ALWAYS USE AN ALIGNMENT PIN TO LINE UP BOLT HOLES. NEVER

Lay out the frame panels male-to-female accordingly. Place the panels so that they can be easily assembled with the carriage rail on the inside and at the bottom of the assembled frame. Note: If a 2 foot (.6 m) frame section will be used, it should be installed on one end of the machine or the other unless otherwise specified by the machine design.

Choose a level working area to assemble the C-650. The machine may be assembled at the job site and run over the slab under its own power, or it may be lifted into place with a crane or other suitable lifting device.

008-0115

Before laying out the component parts for assembly, take the following factors into consideration: 1. Overall width of the machine: For square pours (where the machine frame is perpendicular to the bogie rails or forms), the machine should be at least 5 feet (1.5 m) wider than the width between the slab forms or bogie rails on which the bogies will travel (for example, if the slab will be 20 feet (6.1 m) wide, the 650 frame must be at least 25 feet (7 m) wide). 2. Direction of pour: Decide what direction the machine will move when it is operated. The front of the machine will face the paving operation. The left and right ends will be determined by standing behind the machine and looking in the paving direction.

Starting at the end of the frame opposite of the console, lift up the end panel so that its pin connectors are on the bottom. Lift a frame panel so that its male to female pin connectors are on the bottom and facing towards the lifted end panel (if the machine is a C-650-F, and is equipped with self-widening panels, attach it to the end panel).

3. Console position: The console can be installed on either end of the machine with the controls facing towards the end of the machine. For machines equipped with a single-drum undercarriage, the console should be on the end of the machine that allows the operator to see the finish pass of the drum, and on the same end of the machine as the stationary jacks (C-650-F only). The console should also be on the high side of a

3-1

C-650-F/S 008-0112

holes in the ends of the braces line up with the holes in the top of the self-widening panels. 047-0306

Insert the pins on a cross arm down through the sway braces and into the holes in the top of the frame section.

Bring the male and female pin connectors on the end panel and self-widening panel together and insert a tapered pin. Secure the tapered pin with a hair pin. Lift the another matching panel and connect it with a tapered pin and hair pin to the end panel.

008-0066

008-0244

Hose holder installed on rear of frame

Push the cross arm down until a picker pin can be inserted through the holes in the frame tube and both cross arm pins. On the front of the frame, place a flat washer on the picker pin and secure the pin with a cotter pin. On the rear of the frame, place a hose holder and flat washer on the picker pin and secure with a cotter pin (install hose holders on the rear of the frame only).

Attach the top of the end panel to the tops of the selfwidening panels with 5⁄8 inch x 2 inch (16 x 51 mm) bolts, flat washers, lock washers, and nuts. Install the flat washers on the slotted hole sides of the bolts. Tighten both nuts securely. 008-0245A

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WARNING!

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TO PREVENT FRAME DAMAGE AND SERIOUS INJURY, INSTALL TWO PICKER PINS THROUGH ALL CROSS ARMS. Place the next pair of sway braces diagonally across the top of the frame and align their holes with those in the first pair of sway braces and the top of the frame. Install a cross arm, picker pins, hose holders (on the rear of the frame), washers, and cotter pins. Repeat to install sway braces and cross arms in the remaining holes in the frame panels.

Place two sway braces diagonally across the top of the self-widening panels in the shape of an “X” so the

3-2

C-650-F/S NOTE: The powered transition assembly (PTA) may be installed at any pin-connected joint. If one or more PTAs will be installed in the frame, assemble the frame sections on both sides of the PTA(s), then readSection 03—Install the Powered Transition Adjuster (PTA) to install the PTA(s) in the frame.

•The hose reel mount cross arms have two holes drilled through the center of the top flange. Install the two hose reel mount cross arms in adjacent sets of holes as close as possible to the center of the machine—but not across a frame joint in which a PTA will be installed. Install the hose reel mount cross arms so that the openings in the main C-shaped beams face away from each other.

008-0117

•Do not install cross arm in the last two sets of holes on the console end of the machine (the operator’s platform will be installed using those holes). •If the machine is equipped with a one-piece transport axle assembly, leave out the third to last cross arm on the console end of the machine (it will be replaced by the transport axle). If the machine is not equipped with a transport axle assembly, or is equipped with a twopiece transport axle assembly, install a cross arm in the third set of holes from the console end of the machine. After the machine frame is assembled to the correct width, locate the remaining end panel and connect it to the main frame sections using two tapered pins and hair pins and the bottom, and two 5⁄8 inch (16 mm) bolts, flat washers, lock washers, and nuts the top (install the flat washers on the slotted hole side).

Raise the assembled frame section slightly and block up. Lift the next required frame panels into place and align the male/female pin holes in the bottom of the panels. Insert tapered pins and secure the tapered pins with hair pins. 008-0248

075-0079

Use a suitable lifting device to raise the operator’s platform to the top of the end frame end section so the opening for the console is towards the center of the frame. Align the holes in the operator’s platform with the holes in the top of the frame panels.

Install 5⁄8 inch (16 mm) bolts, lock washers, and nuts in the holes below the upper flange and tighten securely on each side (be sure to install the flat washer on the slotted hole side). The blocks under the frame joint may have to be removed to ease tightening. 016-0052

Console

Transport axle Hose reel

PTA

016-0052

Continue assembling the main frame until it is at least 5 feet (1.5 m) wider than the pour, taking note of the following:

3-3

C-650-F/S 075-0032

Section 03—Install the optional Powered Transition Adjuster (PTA) 016-0026B

Powered transition adjustor (PTA) installed

Push four T-pins down through the platform and the frame. Insert a clevis pin through each of the holes in the frame tubes and the cross arm pins. Place flat washers on the retaining pins and secure the pins with cotter pins.

The Powered Transition Adjustor (PTA) changes the crown of the machine frame and is controlled from the operator’s console. The PTA may be used to set a fixed crown or operated on-the-go for crown changes during the pour. A PTA may be mounted in any joint in the frame and multiple PTA assemblies can be mounted on the machine for multiple crown points. The PTA must be installed in a frame joint directly above the crown point.

075-0031

NOTE: The jack mounts may have to be adjusted to the left or right to position the PTA frame joint directly above the crown point. To reduce PTA assembly and adjustment time, set the machine frame on a totally flat surface before installing the PTA. If the PTA will be installed during machine assembly, assemble the machine frame on both sides of the joint(s) where the PTA(s) will be mounted. Do not install the cross arms on either sides of the PTA joint(s) (unless a hose reel cross arm must be installed), and leave out the sway braces that would cross the joint if it were assembled normally. D

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DANGER!

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TO PREVENT INJURY OR DEATH, USE ADEQUATE BLOCKING UNDER THE FRAME WHEN MAKING THE FOLLOWING ADJUSTMENTS. USE CAUTION WHEN LIFTING THE GRADE JACKS. If the machine is already assembled, remove all the jack mounts and set the frame on a totally flat surface or leave the jack mounts installed and safely block the frame of the machine up on the ends and on both sides of the frame joint where the PTA will be installed (make sure both sides of the PTA joint are totally flat and level). Remove the cross arms from either side of

3-4

C-650-F/S the PTA joint and remove the sway braces that cross the joint. Remove the two 5⁄8 inch (16 mm) bolts and 3⁄4 inch (19 mm) tapered pins and separate the sides of the joint slightly so that the vertical arms of the PTA will fit in the joint.

out so that the distance between the turnbuckle holes on the front and back of the assembly equals the distance between the vertical arm holes. Measure both turnbuckle threads on the left side of the PTA assembly and turn the threads in or out until both turnbuckles are the same length. Repeat for the turnbuckles on the right side of the assembly.

008-0429

034-0171A

Lower vertical arms into place, align bottom holes, and insert long tapered pin

Transition pointer

When the frame on both sides of the PTA is level and aligned, use a suitable lifting device to lower the outside vertical arms down into the frame joint on the front and back of the frame. Use a suitable lifting device to lower the inside vertical arms down into the outside vertical arms.

Use a suitable lifting device to raise the PTA motor and turnbuckle assembly up between the vertical arms of the PTA. Turn the assembly so that the transition pointers face towards the console end of the frame. Use a PTA brace pin to attach each of the four PTA braces to the tops of the PTA vertical arms and the PTA turnbuckles. Secure the brace pins with cotter

Slide the machine frame together at the PTA joint and use an alignment pin to with line up tapered holesofin the bottom of the frame thethe holes in thepin bottom the PTA vertical arms. Slide a long tapered pin through the frame panels and the PTA vertical arms at the front and back of the frame joint. Secure the tapered pins with hair pins.

pins. Lower the PTA braces to the top of the machine frame and insert a cross arm down through the PTA braces and into the cross arm holes in the frame on either side of the PTA joint. Insert a bolt down through each PTA brace and the top of the machine frame and install a lock washer and nut. Tighten securely.

008-0443

Before installing the PTA motor and turnbuckle assembly, measure the distance between the center of the holes on the tops of the vertical arms. Turn the front and rear turnbuckles on the PTA assembly in or

3-5

C-650-F/S 047-320

008-0150A

Use the formula below to determine the distance between the end of the frame and the outside edge of the slipform jack mount (C-650-S)

Route the PTA hoses along the frame over to the console and connect the quick couplers to the “PTA” quick couplers on the console.

IN INCHES:

Clean quick couplers thoroughly before connecting them to prevent dirt from entering the hydraulic system. When connecting quick couplers, be sure they are lined up to prevent damage to the o-rings inside. After quick-couplers are connected, always connect the dust caps together to keep them clean.

1

⁄2 Frame Width - (1⁄2 Slab Width + 26)

IN CENTIMETERS: 1

⁄2 Frame Width - (1⁄2 Slab Width + 66)

To install the jacks, use a suitable lifting device to raise the end of the frame about 2 feet (60 cm) off the ground.

Section 04—Install the stationary jack mounts (standard or slipform mounts)

008-0249

If the machine is a C-650-F, it will be equipped with two or four stationary jacks. If two stationary jacks are included, install them on the console end—opposite from self-widening or power-widening jacks. If four stationary jacks are included, install them on all four corners of the machine above the points where the bogie rails or slab forms will be. If the machine is a C-650-S, install the slipform jack mounts on all four corners of the machine. If the slab will be centered on the machine frame, use the following formulas to deterimine the distance between the outside of the mounts and the outside ends of the machine frame (not including the end panels):

Locate the stationary jack mounts. Remove the four 1 /2 inch x 1 1/2 inch (13 x 38 mm) bolts and the two mounting straps from each stationary jack mount. 008-0121A

Hook the bottom of one of the standard stationary jack mounts under the front of the frame section. If the machine is a C-650-F, install the jack mounts so that

3-6

C-650-F/S the edge of the jack mount is 3-4 inches (76-102 mm) from the end of the frame panel.

Section 05—Install self- or powerwidening jack rails (C-650-F only)

008-0120

If two self- or power-widening jacks are included with the machine, install them on the end of the machine opposite from the console to keep them from interfering with the console and operator. To install the rails, use a suitable lifting device, raise the end of the frame opposite the console and block it up about 3 feet (60 cm) off the ground. W

!

WARNING!

!

TO PREVENT SEVERE INJURY IF THE LIFTING DEVICE FAILS, PLACE BLOCKING UNDER THE RAISED PORTION OF THE FRAME. DO NOT CRAWL UNDER THE FRAME UNLESS ADEQUATE SUPPORT IS IN PLACE.

Use the four 1/2 inch x 1 1/2 inch (13 x 38 mm) bolts and lock washers to fasten the mounting straps to the jack mount on the inside of the machine frame (the frame must be between the mounting straps and the jack mount). Make sure the top and bottom of the jack mount are the same distance from the end of the frame. Tighten all bolts securely.

008-0086A

008-0150A

Self-widening rail attached

Install the rails: Lay a self-widening jack rail on top of the front of the raised end of the frame. Align the bolt holes in the bottom of the rail with the holes in the top of the frame (the part of the rail that will come in contact with the jack mount wheels must be at the front of the frame).

Mount a jack mount to the rear of the frame in the same manner as the front. Before tightening the bolts, square up the rear mount with the machine frame and with the front mount: measure from the end of the frame to the front mount and slide the rear mount to the left or right until it is the same distance from the end of the frame. Make sure the top and bottom of the jack are the same distance from the end of the frame. Tighten all bolts securely.

At both ends of the rail, align the bolt holes in an angle iron stop with the holes in the end of the rail and the frame end panel. Insert a 3⁄8 inch (10 mm) bolt through each hole in the rail and stops and secure with flat washers (on the frame-side of the bolts), and lock nuts. Follow the same procedure to install a rail on the top rear frame (be sure to position the part of the rail

If the machine is equipped with four stationary jack mounts, or if the machine is a C-650-S, repeat the proceedure to install slipform jack mounts on the opposite end of the frame.

that will come in contact with the jack mount wheels at the rear of the frame). Tighten all nuts securely. Follow the same procedure to install rails—but not angle iron stops—on the bottom of the front and rear frame. Tighten all nuts securely.

3-7

C-650-F/S 008-0059A

Section 06—Install the optional powerwidening system (C-650-F only) 008-0058A

Screw bracket installed

Thread a screw bracket about halfway onto the shaft end of the screw (the four mounting holes will align with four holes on the jack mount).

Power-widening drive motor

Thread a nut about 1⁄4 of the way onto the threaded end of the power-widening screw and slide a thrustbearing over the threads after the nut. Insert the threaded end of the power-widening screw into the large hole in the screw support.

Use two 3⁄8 inch (10 mm) bolts, lock washers, and nuts to install a drive motor mount onto the front and rear of the end panel. Install the motor onto the motor mount with two 1⁄2 x 1 3⁄4 inch (13 x 44 mm) bolts, lock washers, and nuts. Tighten all bolts securely. Using a 1 ⁄4 inch (6 mm) key, install a shaft coupler onto each motor shaft. Securely tighten all four Allen screws.

034-0094A

008-0060A

Motor shaft coupler

Install a key and the motor shaft coupler onto the power-widening motor shaft. Install a key onto the coupler end of the power-widening screw and insert the screw into the motor shaft coupler. Make certain the motor shaft and the screw shaft are fully inserted into the shaft coupler. Securely tighten both Allen screws on each screw shaft coupler.

Screw support installed

Install a screw support for the power-widening screws on the front and rear of the machine frame. Insert 1⁄2 inch (13 mm) bolts through the screw support and the two holes the end of the power-widening frame section. Install lock washers and nuts and tighten securely.

3-8

C-650-F/S 008-0060B

034-0098

Tighten both nuts

Attach jack mount to jack rails

Slide a second thrust-bearing onto the end of the screw. Thread the second nut onto the screw after the thrust bearing. Tighten both nuts up against the thrustbearings on either side of the screw supports and securely tighten the two Allen screws on the side of each nut.

Using a suitable lifting device, hang the jack mount on the top rail on the front of the frame. Push the jack mount in so that the groove in the bottom wheels is directly under the bottom rail. 034-0099

Section 07—Install the self- or powerwidening jack mounts (C-650-F only) 008-0354A

Space between wheel and bottom jack rail

Tighten the top wheel adjustment bolts until there is about 1⁄16 inch (2 mm) of space between the bottom rail and the bottom wheels. Slide the jack mount back and forth along the rails to make sure it moves freely (adjust the top wheels as necessary). Self- or power-widening jack wheel adjustment bolts

Loosen the adjustment bolts on the top wheels of a self-widening jack mount enough to allow the top and bottom jack wheels to fit over the jack rails.

3-9

C-650-F/S 034-0100

Notice: To prevent damage to the jacks and mounts, do not raise or lower the jacks more than 2 holes from the bottom set of holes in the jack mounts. If the jacks must be lowered 3 or more holes from the bottom of the jack mounts, jack extensions must be installed (contact your GOMACO dealer or GOMACO for more information). 008-0080A

Jack mount attached to screw bracket

If the optional power-widening assembly has been installed, align the four bolt holes in the center of the jack mount with the holes in the screw bracket. Insert four bolts and install lock washers, flat washers, and nuts and tighten securely. 034-0099A

To install the jacks, use a suitable lifting device to position the jacks up against the jack mount at the correct height. Use an alignment pin to line up the bolt holes in the jacks with those in the jack mount and insert a 1⁄2 x 1 1⁄2 inch (13 x 38 mm) bolt in both top holes and both bottom holes in the jack and mount. Install lock washers and nuts and tighten securely. Install grade jacks on all jack mounts in the same manner. 034-0232A

Turn in the locking screws on the jack mount tight against the bottom self-widening rail to hold the jack mount in position. Mount a jack mount on the rear of the frame in the same manner as the front. Measure from the end of the frame to the front mount and position the rear mount the same distance from the end of the frame. Turn the locking screws on the rear jack mount tight against the bottom self-widening rail to hold the jack mount in position.

Install the bogies (650-F only): Position the drive bogies under the rear grade jacks with the drive motors towards the rear and outside of the machine. Insert connector pins through the jacks and the bogies and secure with hair pins.

Section 08—Install the grade jacks and bogies

If the machine is equipped with four drive bogies, repeat the process above to mount drive bogies on the front grade jacks with the drive motors towards the

Install the grade jacks:To help adjust the finishing drum(s) to the correct slab elevation, the grade jacks can be raised or lowered in 4 inch (10.2 cm) increments.

rear and outside of the machine. If the machine is equipped with two idler bogies, repeat the process above to mount an idler bogie on both front grade jacks.

3-10

C-650-F/S 008-0326

Section 09—Install the tracks. 047-0215

Bogie trainer installed

Before any weight is placed on the grade jacks, install a bogie trainer between the right and left sets of grade jacks. Use a connector pin and hair pin to secure one end of the turnbuckle to the rear jack leg. Adjust the turnbuckle until it reaches the pin connection on the front grade jacks. Secure the turnbuckle with a connector pin and hair pin.

Install tracks

If the machine is equipped with tracks, mount the tracks to the bottom of the jacks. The hydraulic hose quick couplers should face the center of the machine with the track drive motor and gear box on the rear of the machine. The machine may be blocked up, the track drive hoses connected and the tracks driven under the yokes.

008-0084

NOTE: The console may be operated without being mounted on the frame of the machine. 047-0172A

If the bogie trainer is equipped with setscrews, tighten the two setscrews securely before any weight is placed on the bogies. It the bogie trainer is equipped with a turn buckle, tighten the turnbuckle and locknuts securely before any weight is placed on the bogies. NOTE: The bogie trainers must be removed before the machine can turn a radius.

Mount the tracks to the bottom of jacks with two pins. Install a washer on the pin and install the pin through the yoke and track or bogie.

3-11

C-650-F/S 047-171A

016-0084

Install the carriage through the end of the machine frame

Secure the pin in place with another washer and hair pin. 047-0170

Remove the rubber capture wheels from the carriage. Use a suitable lifting device to remove one end panel and lift the carriage up to the carriage rails in the frame. Rotate the carriage so that the undercarriage delay cylinder and the flow divider are towards the front of the machine. Roll the carriage onto the carriage rails and make sure that all the carriage wheels contact the carriage rails. Replace the end panel and tighten all bolts securely. 008-0140A

Install the front, center, and rear track fenders to the yokes on the track. Install pins through the holes in the yokes and the track fenders. Secure the pins in place with hair pins. Follow the same proceedure to install the track and trck fenders on the oposite side of the machine.

Section 10—Install the carriage and console. C

CAUTION! !

Carriage wheel axle locknut

Roll the carriage along the rails from one side of the frame to the other. If the rails are too wide or too narrow for the carriage rails at any point, loosen the lock nut holding the front set of carriage wheels and turn the bolt axle in or out until the carriage can roll freely. In general, allow 3⁄4 inch (19 mm) distance between the wheel and carriage on the rear and 1⁄8 inch (3 mm) on the front adjustment bolts. Tighten the lock nut securely.

!

TO PREVENT MACHINE DAMAGE, DO NOT REMOVE EITHER END PANEL FROM THE C-650 UNLESS THE BOGIE TRAINERS ARE INSTALLED OR THE FRONT AND REAR OF THE FRAME IS SECURELY SUPPORTED.

3-12

C-650-F/S 008-0438A

079-0169

Reinstall the four black rubber capture wheels and adjust each wheel to within 1⁄16-1⁄8 inch (2-3 mm) of the carriage rail. Tighten the capture wheel nuts and locknuts securely.

Use a suitable lifting device to lift the console over the frame with the console controls facing the towards the end of the machine frame. 079-0294

W

!

WARNING!

!

THE OPERATOR MAY BE SERIOUSLY INJURED FROM A FALL FROM THE MACHINE. USE CAUTION WHILE MOUNTING AND DISMOUNTING THE MACHINE. TO PREVENT INJURY TO THE OPERATOR AND PERSONS AROUND THE MACHINE, THE OPERATOR MUST STAY ON THE OPERATOR’S PLATFORM WHILE THE BOGIES OR THE CARRIAGE ARE IN MOTION. 075-0031

Attach the console to the platform with four bolts, flat washers (on the slotted hole side), lock washers, and nuts. Tighten all bolts securely.

Section 11—Install the hose reel assembly 016-0075

Attach each handrail to the operator’s platform with three nuts and tighten securely. Align a ladder with the ladder brackets on the console operator’s platform. Insert a ladder pin through the brackets and the ladder and secure with two hair pins.

The hose reel provides hydraulic fluid to the carriage. To install the hose reel assembly, use a suitable lifting device to place the assembly between the two hose reel mount cross arms so that the two guide rollers are

3-13

C-650-F/S towards the center of the frame. Align the holes and insert four 1⁄2 x 1 1⁄4 inch bolts. Install lock washers and nuts and tighten securely.

Install the E-Stop control box: 008-0353

Clean quick couplers thoroughly before connecting them to prevent dirt from entering the hydraulic system. When connecting quick couplers, be sure they are lined up to prevent damage to the o-rings inside. After quick-couplers are connected, always connect the dust caps together to keep them clean. Connect the quick couplers on the hoses coming from the center hub of the hose reel to the matching quick couplers on the console. Pull the two hoses that are wrapped around the hose reel down through the guide rollers on the reel mount and pull them over to the carriage. Connect the two large quick couplers on the hoses to the matching quick couplers in the center of the carriage.

Bolt the E-Stop box onto the side of the console. Plug the E-Stop “valve” cable in to the “E-Stop valve” bulkhead (B2) in the back of the box. Plug the spade terminal connectors on the end of the “valve” cable onto the terminals on the carriage vented relief coil on the front stage of the pump.

NOTE: The spring tension in the hose reel may have to be adjusted to prevent the hoses from dropping into the concrete or into moving parts. See the directions located on the reel to properly tension the cable.

If the console is not equipped with a travel/vibrator on/ off switch, connect one spade terminal of the black jumper wire from the black-wire side (+12V) of the carriage vented relief coil. Connect the other spade terminal of the black jumper wire to the black-wire side (+12V) of the bogie/vibrator vented relief (if the console is equipped with a travel/vibrator on/off switch, substitute the wires from the switch for the black jumper wire). Make sure the arrow on the diodes between the spade connectors on the vented relief coils are pointed towards the black wires.

Section 12—Install the E-Stop system The E-Stop system comes with one to five E-Stop button(s) (mounted on the console, frame, and/or carriage) and an E-Stop control box mounted on the C-650 operator’s console. A cable reel connects the optional carriage E-Stop button to the E-Stop control box. When any E-Stop button is pushed in, the carriage will stop moving across the frame; the bogies will stop moving the machine; and the drum(s), augers, and vibrator(s) on the carriage will stop. All E-Stop buttons must be pulled out and the E-Stop reset switch must be pushed up before the machine can be operated again.

Plug the E-Stop power cable into the “Power” bulkhead (B1) in the back of the box. Connect the white/blue wire to console ground, the black/brown wire to the accessory terminal of the key switch, and the orange wire to the E-Stop horn/light. Do not connect the red wire (the red wire is not used in the C650). Do not connect the green wire (the green wire can be used as a spare if another wire in the cable fails). If additional E-Stop buttons will not be installed, plug a 6-pin E-Stop button dummy plug into each unused “EStop right/left” or “carriage” bulkhead (bulkheads B4 and/or B3). NOTE: If the bulkheads on the back of the E-Stop box are not connected correctly, the machine will not operate.

3-14

C-650-F/S 008-0364

Section 13—Install the optional electric cord reel 016-0005B

To install E-Stop buttons on the machine frame, bolt an E-Stop button to both sides of the frame so that they can be easily reached in an emergency. Plug the cable from the right side of the machine into the “right” bulkhead on the back of the E-Stop console (bulkhead B4). Plug the cable from the left side of the machine into the “left” bulkhead on the back of the E-Stop console (bulkhead B4).

An electric cord reel connects the optional rotary vibrator lift switch to the lift cylinder solenoid on the carriage. The electric cord reel also can connect an optional carriage E-Stop button(s) to the console EStop box. To install the electric cord reel, first hook the reel mount bracket over the bottom lip on the back of one of the frame sections near the console. Place a clamp around one of the vertical tubes in the frame section. Insert two 1⁄2 inch (13 mm) bolts, lock washers, and nuts and tighten securely.

034-0127

Connect the reel mount to the mount bracket with a hinge pin and secure it with a hair pin. Swing the reel

To install the optional set of four E-Stop buttons, bolt an E-Stop button to each corner of the machine so that they can be easily reached in an emergency. Bolt the left- and right-hand E-Stop cable mounting boxes onto the left and right frame end panels. Plug the E-Stop buttons into the appropriate boxes. Plug the left- and right-hand cable mounting boxes into the “E-Stop right/ left” bulkheads (bulkheads B3 and B4) on the back of the console E-Stop box.

mount into a horizontal position and connect a turnbuckle between the reel mount and the mount bracket with pins. Secure the turnbuckle pins with hair pins. Adjust the turnbuckle until the reel mount is horizontal. Tighten the turnbuckle locknut securely and install another turnbuckle in the same way on the other side of the cable reel mount. Attach the reel to the top of the reel mount with four 1⁄2 inch (13 mm) bolts, lock washers, and nuts. Tighten securely. When the carriage and carriage option mounting kit have been installed onto the carriage, slide a cable mount clamp onto a carriage weight or float pan mounting tube on the back of the carriage (install the mount clamp onto the mounting tube that is on the same side of the machine—left or right—as the cable reel). Securely tighten all setscrews. Pull the electric cable through the guide rollers on the reel mount and extend it to the carriage. Clamp the cable to the clamp mount on the mount tube. Align the clamp mount with the guide rollers on the reel mount and tighten the mount clamp.

3-15

C-650-F/S 016-0077

008-0330

Route the and bogie or track the rear of the frame place themmotor in thehoses hose along hangers. Connect the cable from the reel to the cable from the carriage. Twist the connectors after they are fully inserted to lock them together. Connect the cable from the reel to the cable from the console. Twist the connectors after they are fully inserted to lock them together. NOTE: The spring tension in the cable reel may have to be adjusted to prevent the cable from dropping into the concrete or into moving parts. See the directions located on the reel to properly tension the cable.

Stand behind the machine and face towards the direction of travel to determine the left and right sides of the machine. Connect the hoses from the left drive bogie(s) or track to the “left” bogie or track quick couplers on the console. Connect the hoses from the right drive bogie(s) to the “right” bogie or track quick couplers on the console marked. NOTE: If the machine is equipped with four drive bogies, the bogie motors on each side of the machine are connected with jumper hoses in series. 047-0175

Section 14—Install the hydraulic hoses C

!

CAUTION!

!

TO PREVENT DAMAGE TO HYDRAULIC HOSES, ROUTE THEM OVER THE FRAME AND OUT OF THE WAY OF THE CARRIAGE AND OTHER MOVING PARTS. To prevent dirt from entering the hydraulic system, thoroughly clean quick couplers before connecting them. To prevent damage to the o-rings, be sure quick couplers are lined up before connecting them. Always connect the dust caps together after connecting quick couplers. If the machine is equipped with hydraulic jacks, thoroughly clean all hose fittings to prevent dirt from entering the hydraulic system. Connect the hoses from the jack lift cylinders to the appropriate quick couplers on the operators’ console. Place the hoses in the hose hangers. Loop any excess hose and tie it to the frame to keep it away from moving parts.

Section 15—Install the undercarriage The undercarriage with double drums and augers finishes concrete in one pass across the slab before the machine moves forward.

3-16

C-650-F/S 008-0253B

The undercarriage with a single-drum or Vib-O-Pac 100 installed finishes the concrete in two passes across the slab before the machine moves forward. The undercarriage with a single, reversing Vib-O-Pac 200 drum installed finishes the concrete in one pass across the slab before the machine moves forward. If the machine will be equipped with an optional hydraulic lowering kit (shown on the undercarriage below), install it onto the undercarriage before mounting the undercarriage on the machine. Attach the kit to the undercarriage with eight 1⁄2 x 1 1⁄4 inch (13 x 32 mm) bolts and Nylox lock nuts. Tighten all securely.

To prevent cross threading the undercarriage connecting bolt, precisely align the undercarriage and the carriage before carefully tightening the bolt into the nut weldment on the carriage. Leave the bolt loose enough to allow the undercarriage to pivot.

008-0359

008-0334

To install the undercarriage, first raise all four corners of the machine with the grade jacks. Use a suitable lifting device to slide the undercarriage under the carriage. Rotate the undercarriage so the auger shafts point towards the front of the machine (towards unfinished concrete). If the undercarriage is equipped with adjustable augers, turn the undercarriage so the drum drive chain(s) are at the rear of the machine (towards the finished concrete). 008-0333A

Place a flat washer on the 3⁄4 inch (19 mm) undercarriage connecting bolt protruding through the bottom of the carriage and install a lock nut. If a single-drum undercarriage or Vib-O-Pac 100 is being installed, leave the lock nut loose for now. If a double-drum undercarriage or Vib-O-Pac 200 is being installed, tighten the locknut securely and check to see that the undercarriage still rotates freely (readjust the undercarriage connecting bolt if necessary). 008-0012

Place a lock washer and flat washer on the 3⁄4 x 6 1⁄2 inch (19 x 165 mm) undercarriage connecting bolt and insert it through the center hole in the undercarriage.

If a single-drum undercarriage or Vib-O-Pac 100 is being installed, turn the undercarriage so the locking bracket on the undercarriage is two holes off center

3-17

C-650-F/S 008-0198A

and the auger shaft points away from the operator’s console. 008-0335

If a single-drum undercarriage or Vib-O-Pac 100 is being installed, position four locking clamps over the turntable ring on the carriage. Install a 1⁄2 inch (13 mm) bolt, lock washer, and nut through each clamp and tighten securely.

If a double-drum or Vib-O-Pac 200 is being installed, use 1⁄2 x 1 1⁄2 inch (13 x 38 mm) bolts, flat washers, lock washers, and nuts to install the undercarriage wheels onto the undercarriage around the turntable ring on the carriage. Tighten all nuts securely. 008-0343

008-0253A

If a double-drum being use eightor3⁄8Vib-O-Pac x 1 inch (10200 x 25ismm) bolts, lock installed, washers, and nuts to install the angle of attack shifting cylinder mounts on the carriage and undercarriage. Tighten all bolts securely. If a single-drum undercarriage or Vib-O-Pac 100 is being installed, insert a 1⁄2 inch (13 mm) bolt through the holes on the carriage turntable and the locking bracket on the undercarriage. Install a flat washer, lock washer, and nut and tighten securely. Tighten the 3 ⁄4 inch (19 mm) center bolt, locknut, and the four locking clamps securely.

008-0344

If a double-drum or Vib-O-Pac 200 is being installed, slide the angle of attack cylinder yokes over the mounting pins with the rod end of the cylinder attached to the undercarriage. Secure the cylinder to the mounts with hair pins.

3-18

C-650-F/S 008-0057

C

!

CAUTION!

!

CONTINUOUS EXPOSURE TO ENGINE NOISE CAN CAUSE HEARING DAMAGE. DO NOT OPERATE MACHINE WITHOUT HEARING PROTECTION. Before starting the engine, make sure everyone is away from all moving parts. Pull out the throttle about half way and start the engine. Push in the throttle until the engine slows down to just above idle speed. Make sure all E-Stop buttons are pulled out. Push the EStop reset switch up to the “reset” position to reset the E-Stop system. To start rotating the drums, stand clear of the drums and augers and place the carriage travel valve in the “on” position. Stand in front of the machine, face the drums, and compare drum rotation to that shown in the appropriate section below.

Connect the two male quick couplers from the singledrum, double-drum, or Vib-O-Pac undercarriage to the two female quick couplers from the carriage. Clean quick couplers thoroughly before connecting them to prevent dirt from entering the hydraulic system. When connecting quick couplers, be sure they are lined up to prevent damage to the o-rings inside. After quick-couplers are connected, always connect the dust caps together to keep them clean.

If the drum(s) rotate in the wrong direction, place the carriage travel valve in the “off” position and shut off the engine. Reverse the drum motor hoses at the quick-couplers or drive motor(s) and repeat the procedure above to verify correct drum rotation. When drum rotation is correct, place all controls in the “neutral” or “off” position and shut off the engine.

Section 16—Check drum rotation To check drum rotation, first place the carriage vibrator variable control(s) in the “0” position to turn off the carriage vibrator. If the carriage or console are equipped with an optional vibrator on/off switch, place

Single-drum and Vib-O-Pac 100 rotation: 008-0399

Console on left side of machine

the switch in the “off” position. Place the carriage travel valve (on the console) in the “off” position. Place the carriage variable travel speed control valve (on the carriage) in the “off” position. Make sure the travel direction control valve is in the “neutral” position. Make sure the variable travel speed control valve is in the “off” position.

Drum

Console on right side of machine

W

!

WARNING!

!

SEVERE INJURY CAN OCCUR TO PERSONNEL ON OR AROUND THE MACHINE IF THEY ARE CAUGHT IN ANY MOVING PARTS WHEN THE ENGINE IS STARTED. MAKE CERTAINALL PERSONNEL ARE CLEAR OF THE MACHINE BEFORE THE ENGINE IS STARTED. C

!

CAUTION!

Drum 008-0399

If the machine is equipped with a single-drum undercarriage, the bottom of the drum should spin towards the operator’s console (see the “Single-drum rotation” drawing above).

!

TO PREVENT MACHINE DAMAGE, CHECK THE ENGINE AND HYDRAULIC OIL LEVELS BEFORE STARTING THE ENGINE.

3-19

C-650-F/S Double-drum rotation:

Section 17—Install the standard auger(s) and auger guard

034-0134

DRUMS

008-0122A

034-0134

If the machine is equipped with a double-drum undercarriage, the bottom of the drums should be turning towards one another: the drum on the right should be rotating clockwise and the drum on the left should be rotating counterclockwise (see the “Doubledrum rotation” drawing above).

Double-drum augers 008-0338

Slope-pour drum rotation: 008-0400

Console

um Dr

If the machine is not equipped with adjustable augers,

If the machine will be used to finish a sloped surface, the bottom of the drum must spin towards the top of the slope (see the “Slope pour drum rotation” drawing above).

the correct auger must be installed on the correct drum: the auger(s) must move the concrete forward during pouring operations. Face the carriage and install the white auger on the drum which turns clockwise. Install the yellow auger on the drum which turns counterclockwise. Slide the proper auger over the proper shaft, leaving about 1 1⁄2 inches (35 mm) between the flighting on the auger and the undercarriage frame. Tighten the setscrews securely.

008-0400

008-0135

To install the auger guard, tip the auger guard up and insert the 90° bends into the holes provided on the

3-20

C-650-F/S 008-0342

front of the undercarriage. Lower the auger guard to lock it into place. W

!

WARNING!

!

TO PREVENT SERIOUS INJURY, DO NOT STAND OR SIT ON THE AUGER GUARD.

Section 18—Install the carriage drive chains To install the carriage drive chains, first push the carriage to the center of the frame.

Take the free end of the chain over to the end panel opposite the console and feed it out through the chain hole in the front of the frame. Pull the chain tight by hand and attach it to the chain hook. Remove excess chain.

008-0342

Repeat the process above to install the second chain on the back of the frame. Tighten the rear chain evenly with the front chain. Remove the clamps holding the carriage in place.

Section 19—Mount the sensors (C-650-S only) 047-388A

Feed one end of the first chain out through the hole in the front of the end panel on the console side of the machine and attach the end to the chain hook. 016-0085

Take the free end of the first chain over to the carriage. Pull the chain tight by hand and feed the chain under the first idler sprocket on the front of the carriage, over the center drive sprocket, and under the second idler sprocket on the front of the carriage.

The sensor mounts can be installed in the top or bottom ofdifference holes on the grade between jacks (there a and 6 inch (15set cm) in height the is top bottom sets of holes). The standard position is in the top position. Mount a sensor mount to each grade jack with four bolts, lock washers, and nuts. Tighten securely.

3-21

C-650-F/S 047-389

047-391

Install a sensor pivot mount on the bottom of each sensor mount with a bolt and lock washer. Install the pivot mount with the longer portion pointed toward the stringline (the long portion may also be pointed towards the center of the machine). 047-392

Install the sensor mount tube into each mount. Install a bolt through one of the holes in the mount tubes and secure with a lock washer and nut (the stringline height determines which hole to use). 047-390

Install a turnbuckle mount on each sensor arm with the turnbuckle eye pointed up. 047-393

Install a pivot cap on the bottom of each mount tube with two bolts and lock washers. Install the pivot mount bolt through the pivot cap before tightening the bolts to ensure proper alignment.

Determine which side of the machine the steering sensors will be mounted. Install the steering and grade jack assemblies on that side.

3-22

C-650-F/S 047-394

047-396

Mount the grade jack assemblies on the side opposite the steering arms. 047-395

Install the sensors on the bottom of the grade and steering jacks. Mount the sensor for steering control with the hub facing forward and the coil cord facing right (the steering sensors are mounted the same not matter on which side of the machine they are installed). Mount the sensor for grade control on the right side with the hub pointed right and cord pointed forward. 047-397

Install a turnbuckle mount to the top of each sensor mount tube with a bolt and lock washer. If the sensor arms are extended far enough to become unstable, install turnbuckles with the clevis pins. Secure the clevis pins with cotter pins

Mount the sensors for grade control on the left side of the machine with the hub pointed left and the coil cord facing forward.

3-23

C-650-F/S 047-0603

grade wand in the up position and the steering wand away from the machine frame. 047-3102

With the roll pin centered, mount both the front and rear steering wands perpendicular to the main frame on the front and rear steering sensor hubs. Tighten the attaching thumb screws securely.

Connect the front and rear sensors to the correct bulkheads on the top of the end panels. C

!

047-399B

CAUTION!

!

WHEN THE SENSORS ARE DISCONNECTED, PLACE DUST CAPS OVER THE ELECTRICAL PLUGS TO KEEP MOISTURE AND DIRT OUT.

Section 20—Install the slipforms (C-650-S only) 016-0101

With the roll pin centered, mount the all four grade wands parallel to the main frame with the round tube pointed forward and away from the machine on the grade sensor hubs. Tighten the attaching thumb screws securely. 047-3101

Insert the slipform jacks down into the tubes on the jack mounts. Lower the jacks until the bottom of the rods are higher than the top of the slipforms and tighten the setscrews. Place the slipforms under the slipform jack rods and brace the slipforms upright so that the slipform

Adjust the spring tension on the grade and steering sensor hubs just enough to hold the roll pin in contact with the stop pin. Adjust the spring tension to hold the

mountingthe brackets areso directly below the guards jacks. are at Position slipforms that the splash the front of the slipforms.

3-24

C-650-F/S 016-0107

NOTE: The slipform jacks and springs may have to be readjusted after the carriage rails are set to the correct profile and the machine frame is set to the proper grade. C

!

CAUTION!

!

TO PREVENT SERIOUS EYE INJURY, ALWAYS WEAR SAFETY GLASSES OR FACE SHIELDS WHEN INSTALLING WEDGE BLOCKS. 016-0116

Use the track legs to raise or lower the machine until it is close to the same height as it will be during paving operations. Turn the front slipform jack T-handles to raise or lower the jack screws until there is at least 1 inch (2.5 cm) of thread above the inner tube of the jacks (the extra thread at the top of the jacks will allow for final adjustments). Loosen the two set screws on each jack outer tube and lower the inner tubes in the jacks until the jack rods can be inserted into the mounts on the side of the slipforms (if possible, do not lower the tops of the inner tubes down past the tops of the outer tubes). Tighten all setscrews securely. 016-0104

Install wedges in each jack mount on the sides of the slipforms to eliminate shifting or pivoting of the slipforms during paving operations. To install each wedge, place it behind a slipform mount. Use a hammer to insert the wedge and lock the mount pin into position. Insert a bolt with a flat washer through the slotted hole in the wedge and into the threaded hole in the back side of the slipform. Tighten securely. 016-0102

Align the holes in the bottom of each jack shaft with one of the slotted holes in the slipform mounting brackets. Insert clevis pins and cotter pins or bolts, lock washers and nuts and tighten securely. While the slipforms are resting on the final grade of the slope, turn the slipform jack T-handles to compress the springs a small amount.

Measure the distance between the slipforms at the front and rear jacks. If the distance is not correct, or if the slipforms are not parallel, use a suitable liftiing device to raise the machine and move the slipform jack mounts to the left or right. Recheck the distance between the jacks and readjust if needed. Tighten all jack mount bolts securely.

3-25

C-650-F/S 056-011

Install optional slipform extensions: 016-0132

Turnbuckle and locknut

Position the Spanit sections with the pin connectors on the bottom. Connect the male and female pin connectors and insert clevis pins through the holes. Secure the clevis pins with a cotter pins.

If the slipforms are equipped with slipform extensions, hold a straight edge up to the inside face of the extensions and make sure the extensions are straight. If either extension is not straight at some point, loosen the lock nuts and rotate the appropriate turnbuckle(s) until the extension is straight. Tighten all lock nuts securely.

056-0012

016-0121

To attach each slipform extension to the rear of both slipforms, lift the form lock on the slipform extension and insert the guide plate at the rear of the front slipform into the front of the slipform extension. Lower the form lock onto the pin on the rear of the slipform and tighten the lock nut securely.

Section 21—Install the optional Spanit If the machine is equipped with an optional Spanit workbridge, place the Spanit sections in the work area. Begin assembly of the Spanit sections starting at one side of the canal and finish at the other side of the canal. The Spanit sections equipped with cleats are used on the slope sections of the Spanit. Sections without cleats are used in the bottom of the canal.

Tip the sections of Spanit up towards each other and install two bolts, lock washers and nuts. Tighten securely. Repeat the procedure above until the slope sections are assembled. Connect the bottom wedge assemblies to the bottoms of the slope sections with pins, cotter pins and bolts, lock washers and nuts. Tighten securely. Position the bottom Spanit sections so the pin connectors engage the bottom slope wedge assemblies. Insert pins and secure with cotter keys. Insert bolts, lock washers and nuts and tighten securely.

3-26

C-650-F/S C

!

CAUTION!

!

TO PREVENT SERIOUS INJURY OR DEATH, MAKE SURE EVERYONE IS AWAY FROM THE LIFT AREA BEFORE LIFTING ANY PART OF THE MACHINE. Use an adequate lifting device to raise and support the Spanit with adequate blocking.

Insert the pins on the bottoms of the Spanit mount assemblies into the first set of open brackets on the slipforms directly behind the machine. Align the hole in the shaft of the jack with one of the slotted holes in the slipform mounting bracket. Insert a clevis pin and cotter pin or a bolt, lock washer and nut and tighten securely. C

!

016-0120

CAUTION!

!

TO PREVENT SERIOUS EYE INJURY, ALWAYS WEAR SAFETY GLASSES OR FACE SHIELDS WHEN INSTALLING WEDGE BLOCKS. 016-0116

Spanit mount assembly

The Spanit is attached to the slipform with two mount assemblies which clamp to the bottom of the Spanit and are attached to the slipforms. NOTE: Install the Spanit mounts in the first open mount brackets on the slipforms directly behind the machine.

Insert wedge blocks

Place wedges behind the Spanit mount pins. Use a hammer to insert the wedges and lock the mount pins into position. Insert a bolt with a flat washer through the slotted hole in each wedge and into the threaded hole in the back side of each slipform. Tighten securely.

016-0103

016-0108

Attach Spanit to mounts

Attach Spanit mount assemblies to slipform

Remove the bolts, lock washers, and clips from the top of both Spanit mounts. Use an adequate lifting device to raise the Spanit onto the top of the mounts.

3-27

C-650-F/S Reinstall the clips over the bottom tubes in the Spanit frame. Reinstall the bolts and lock washers and hand tighten for now.

Section 22—Install the undercarriage shift stops 008-0423A

016-0094

Shift stop

Shift stop

Reversing pushed towards right side ofshaft machine by carriage shift stop

Measure between slipforms at the Spanit mounts

Measure the distance between the slipforms at the Spanit mounts. If the distance is not correct, move the slipforms in or out. 016-0108

Reversing pushed towards left side of shaft machine by carriage shift stop 008-0423a

The undercarriage shift stops push the reversing shaft in the carriage to the right or to the left, depending upon which side of the machine the carriage is on. The reversing shaft rotates the carriage shift control valve in the carriage. The carriage shift control valve reverses the direction in which the carriage is traveling. If the carriage is equipped with double drums, the carriage shift control valve also shifts the undercarriage to the correct angle of attack. If the carriage is equipped with a rotary stinger vibrator, the carriage shift control valve also rotates the vibrator 180° to a new angle of attack. To install the shift stops, place all controls on the console and carriage in the “neutral” or “off” position. Rotate the carriage variable travel speed control valve on the carriage clockwise in the “increase” direction until it is on the number “1” or “2” position. W

!

WARNING!

!

SEVERE INJURY CAN OCCUR TO PERSONNEL ON OR AROUND THE MACHINE IF THEY ARE CAUGHT IN ANY MOVING PARTS WHEN THE ENGINE IS STARTED. MAKE CERTAIN ALL PERSONNEL ARE CLEAR OF THE MACHINE BEFORE THE ENGINE IS STARTED.

Tighten Spanit mount bolts securely

Tighten the 4 bolts on the top of each Spanit mount securely. D

!

DANGER!

!

TO PREVENT SEVERE INJURY OR DEATH FROM FALLS, KEEP EVERYONE OFF THE TRUSS ASSEMBLY. DO NOT USE THE TRUSS ASSEMBLY AS A WORKBRIDGE. TO PREVENT SEVERE INJURY OR DEATH FROM FALLING OBJECTS, DO NOT STORE ANYTHING ON THE TRUSS ASSEMBLY. Repeat the proceedure above to install any additional spanit or truss assemblies.

Start the engine and adjust the throttle so that the engine is running at just above idle speed. Move the E-Stop reset switch up to reset the E-Stop system. W

!

WARNING!

!

TO PREVENT SERIOUS INJURY KEEP HANDS AND FEET CLEAR OF THE CARRIAGE RAILS, CARRIAGE CHAINS, AND THE BOGIE RAILS WHILE MOVING THE CARRIAGE OR BOGIES.

3-28

C-650-F/S 034-0143

opposite side of the frame in the same manner as the first. When both shift stops are installed, allow the carriage to slowly move back and forth across the frame. If the carriage does not shift at the correct points along the frame, shut off the engine and move the shift stop towards the inside or outside of the frame (additional adjustments may be necessary after the machine has begun paving).

Section 23—Install the float pan(s) 008-0348

Carriage over edge of slab

Place the carriage travel valve in the “on” position to start the carriage moving along the frame (the carriage may take a second or two to start moving). Let the carriage move slowly in either direction along the frame until it is over the approximate spot where the edge of the slab will be (make sure no part of the drums or augers will come into contact with the jacks, bogies, tracks, slipforms or slab forms). Place the carriage travel valve in the “off” position to stop carriage movement. Shut off the engine.

Single-drum float pan rod

008-0323

If the undercarriage is equipped with a single-drum, insert the float pan rod into the hole on the rear of the undercarriage and through the hole on the front of the undercarriage. Push the rod into the undercarriage as far as it will go. Install a flat washer over the auger end of the rod and secure it with a hair pin (make sure the washer and pin do not interfere with any moving parts). 008-0375

Undercarriage shift stop installed

Remove the bracket bolt and bracket from one undercarriage shift stop and hang the shift stop on the rear carriage rail between the carriage and an end panel (the spring should point towards the carriage). Slide the stop along the rail until the plunger contacts and pushes the undercarriage shift knob and reversing shaft completely in. Reinstall the shift stop bracket and bracket bolt and tighten securely. Start the engine and run it just above idle speed. Place the carriage travel valve in the “on” position to start the carriage moving in the opposite direction (the carriage may take a second or two to start moving). Install a second undercarriage shift stop on the

Double-drum float pan rod If the undercarriage is equipped with a double-drum, tip the float pan hanger up and align the ends of the rods with the 3⁄4 inch (19 mm) holes in the back of the undercarriage. Lower the back down into place.

3-29

C-650-F/S 008-0187

securely. If the hanger weldment is equipped with an adjustable screw jack, turn the handle to the right or left until the jack is extended about half its total length (this will allow for full up-and-down movement when the float pan is installed). 008-0349

Float pan extension tubes

If the carriage is equipped with an adjustable float pan, slide the float pan extension tubes into the vibrator mount tubes and tighten the 1⁄2 x 1 1⁄4 (13 x 32 mm) inch set screws securely. Float pan installed

008-0362

Install the float pan(s) after the pour has started and the machine has advanced far enough to set the float pan(s) on to the concrete. Connect the float pan chains to the inside or outside chain hangers on the rod or hanger(s) so that the pan(s) float freely in both directions across the finished surface and remove any small marks. To produce the best finish, the chains may have to be adjusted so that the front of the pan is lifted off the finished surface slightly when the carriage is travelingwith in either direction.jack, If the floatsmall pan hanger equipped an adjustable make up or is down adjustments to the jack to produce the best finish. Single adjustable float pan assembly

NOTE: When pouring low-slump concrete, a small weight may added to the float pan(s) to obtain the desired finish.

008-0004

Section 24—Install the optional pan vibrator NOTE: If the carriage will be equipped with a pan vibrator and optional adjustable augers, install the pan vibrator behind the adjustable auger assembly.

Double adjustable float pan assembly

Slide the float pan hanger weldment onto the extension tubes so that the float pan(s) will travel a few inches or centimeters behind the drums. Tighten all clamp bolts or 1⁄2 x 1 1⁄4 (13 x 32 mm) inch set screws

3-30

C-650-F/S 008-0056

008-0179

Pan vibrator installed behind adjustable augers The pan vibrator consolidates a variety of materials in overlays or when reinforcing steel is close to the finished surface.

Vibrator hanger tube installed

NOTE Install the pan vibrator after the carriage and the undercarriage are installed. If the carriage is equipped with adjustable augers, install them in front of the pan vibrator. If the undercarriage is equipped with standard augers (mounted to the front of the finish drum shafts), make sure the auger guard is installed correctly before installing the pan vibrator. 008-0426A

Slide the hanger tubes into the front of the carriage as shown above. Leave enough of the tubes exposed in front of the carriage so that all the equipment that will hang from the tubes (adjustable augers and/or pan vibrator) can be installed onto the tubes. Tighten the hanger tube setscrews securely. If the hose have not been installed on the pan vibrator, install two JIC fittings in the vibrator motor and tighten securely. Attach the hose with the female quick coupler to the fitting on the right side of the motor (as seen from the rear of the motor). Install the hose with the male quick coupler to the fitting on the left side of the motor (as seen from the rear of the motor). 008-0425

To install the pan vibrator, first slide a pan vibrator mount clamp onto both hanger tubes (to be installed in the front of the carriage). If the mount clamps are equipped with setscrews, do not tighten them at this time. If the mount clamps are equipped with 3⁄8 x 3 inch (10 x 76 mm) bolts, install a flat washer on each bolt, install the bolts, and install flat washers and Nylox nuts. Do not tighten at this time.

Use a suitable lifting device to raise the pan vibrator assembly up between the mount clamps. Use four bolts, lock washers, and nuts to attach the vibrator assembly to the mount clamps. Securely tighten the nuts holding the assembly to the clamp. Square the pan vibrator with the hanger tubes and move it as close as possible to the undercarriage (make sure it stays clear of any stationary augers). Tighten the clamp nuts securely to fasten the vibrator assembly to the hanger tubes. Connect the vibrator quick couplers to the quick couplers coming from the vibrator variable speed

3-31

C-650-F/S control valve. Tie the hoses up and out of the way of drums, augers, unfinished concrete, etc.

install the auger assembly in front of the vibrator. If the carriage is equipped with a rotary stinger vibrator, install the auger assembly behind the rotary vibrator.

Clean quick couplers thoroughly before connecting them to prevent dirt from entering the hydraulic system. When connecting quick couplers, be sure they are lined up to prevent damage to the o-rings inside. After quick-couplers are connected, always connect the dust caps together to keep them clean.

008-0426

C

!

CAUTION!

!

TO PREVENTSYSTEM DAMAGE TO THE THE VIBRA TOR HYDRAULIC , COUPLE VIBRATOR HYDRAULIC LINES FROM THE CARRIAGE VIBRATOR VARIABLE AND OIL TANK TOGETHER AND TURN THE VIBRATOR VARIABLE CONTROL TO THE OFF POSITION WHENEVER THE VIBRATOR IS DISCONNECTED FROM THE CARRIAGE.

Section 25—Install the optional adjustable auger 008-0056

To install the carriage-mounted adjustable auger assembly, first slide a pan vibrator mount clamp onto both hanger tubes (to be installed in the front of the carriage). If the mount clamps are equipped with setscrews, do not tighten them at this time. If the mount clamps are equipped with 3⁄8 x 3 inch (10 x 76 mm) bolts, install a flat washer on each bolt, install the bolts, and install flat washers and Nylox nuts. Do not tighten at this time. Slide the two hanger tubes into the tubes welded to the sides of the carriage. Leave the tubes extended far enough so that all the equipment that will hang from the tubes (augers and/or pan vibrator or rotary vibrator) can be installed onto the tubes.

Adjustable augers installed in front of pan vibrator

NOTE: If the carriage will be equipped with adjustable augers and the optional rotary vibrator, install the augers behind the rotary vibrator assembly. The height of the optional adjustable augers can be adjusted independently from the height of the finishing drums. By raising or lowering the adjustable augers, the height of the concrete in front of the drums can be precisely controlled. The pitch of the augers can also be adjusted so that the augers are level from front to back. GOMACO manufactures two types of adjustable augers: carriage-mounted and undercarriagemounted. NOTE If the carriage is equipped with a pan vibrator, use the carriage-mounted augers and

Use a suitable lifting device to raise the auger assembly up between the mount clamps. Use four bolts (there is one cam bolt in each clamp), lock washers, and nuts to attach the vibrator assembly to the mount clamps. Securely tighten the nuts holding the assembly to the clamps. Square the auger assembly with the hanger tubes and slide it back as far as possible (make sure it stays clear of the undercarriage or pan vibrator). Tighten the clamp nuts securely to fasten the vibrator assembly to the hanger tubes. The adjustable auger motors are plumbed in series with the drum motor(s)—pressure oil from the on/off valve goes through one auger motor, then the other auger motor, then on to the drum motor(s). To connect the auger quick-couplers, first disconnect the 1⁄2 inch quick coupler going from the on/off valve to the drum motor(s). Connect the 1⁄2 inch male quick coupler from the adjustable augers to the 1⁄2 inch female quick coupler connected to the on/off valve. Connect the 1⁄2 inch male quick coupler from the drum motor(s) to the

3-32

C-650-F/S 1

⁄2 inch female quick coupler from the adjustable augers.

The rotary vibrator shift motor automatically rotates the vibrator at each side of the slab. When the vibrator rotates, it consolidates the concrete next to the slab forms and gets in position to be dragged back through the slab by the carriage.

008-0135

008-0179

Auger guard installed

To install the auger guard, tip the auger guard up and insert the 90° bends into the holes provided on the front of the undercarriage. Lower the auger guard to lock it into place. W

!

WARNING!

!

Vibrator hanger tube installed

To install the rotary vibrator assembly, first inser t two vibrator hanger tubes into the two mounting tubes on the carriage. Do not tighten the set screws yet. 008-0177

TO PREVENT SERIOUS INJURY, DO NOT STAND OR SIT ON THE AUGER GUARD.

Section 26—Install the optional rotary vibrator NOTE: the carriage is equipped with adjustable augers, Ifinstall them onto the hanger tubes before installing the rotary vibrator assembly (the augers are mounted behind the rotary vibrator). 008-0164

Insert the short mounting tube through the front of one long hanger tube, through the rotary vibrator mounting tube and through the front of the other long hanger tube. Center the rotary vibrator mount on the short mounting tube and adjust the long tubes in or out until the vibrator clears the augers. Tighten all set screws securely.

Rotary vibrator assembly

The rotary type vibrator can consolidate concrete with or without reinforcing steel. If the concrete does contain reinforcing steel, the steel must be deep enough so that it does not interfere with the vibrator.

3-33

C-650-F/S 008-0165A

W

!

WARNING!

!

SEVERE INJURY CAN OCCUR TO PERSONNEL ON OR AROUND THE MACHINE IF THEY ARE CAUGHT IN ANY MOVING PARTS WHEN THE ENGINE IS STARTED. MAKE CERTAIN ALL PERSONNEL ARE CLEAR OF THE MACHINE BEFORE THE ENGINE IS STARTED. C

! Insert the vibrator mount into the bottom of the lower guide tube. Tighten the set screws securely. NOTE: The vibrator mount should be installed so that it is pushed into the lower guide tube (instead of pulled out of the lower guide tube) by the concrete as the carriage moves across the frame (see the “Correct vibrator installation” photo, below). Attach the vibrator to the vibrator mount and securely tighten the bolts and set screws. The vibrator and vibrator mount may need to be adjusted after the machine is over the slab forms to get better vibration at the edge of the slab. Connect the female quick-coupler from the vibrator to the male quick-coupler coming from the single-coil

CAUTION!

!

TO PREVENT MACHINE DAMAGE, CHECK THE ENGINE AND HYDRAULIC OIL LEVELS BEFORE STARTING THE ENGINE. Place all controls and switches in the “off” or “neutral” position and make sure everyone is clear of the machine. Make sure the vibrator on/off switch on the console or carriage and the vibrator variable on the carriage are in the “off” position. Start the engine, reset the E-Stops, and run the carriage slowly back and forth along the machine frame. C

!

CAUTION!

!

TO PREVENT DAMAGE TO THE STINGER VIBRATOR, DO NOT RUN IT FOR MORE THAN ONE MINUTE UNLESS IT IS SUSPENDED IN CONCRETE OR WATER. 016-0038B

vibrator solenoid valve. Connect the male quickcoupler from the vibrator to the female quick-coupler leading to the hydraulic oil tank. Clean quick couplers thoroughly before connecting them to prevent dirt from entering the hydraulic system. When connecting quick couplers, be sure they are lined up to prevent damage to the o-rings inside. After quick-couplers are connected, always connect the dust caps together to keep them clean. Connect the quick-couplers from the vibrator lift cylinder to the quick-couplers from the double-coil vibrator lift solenoid. Connect the quick-couplers from the rotary shift motor to the quick-couplers that are teed into the undercarriage shift cylinder.

Correct vibrator installation

As the carriage moves across the frame, the vibrator should be dragged across the width of the concrete slab. If the vibrator is not being dragged, place all controls and switches in the “off ” or “neutral” position and shut off the engine. Remove the vibrator mount and turn it around on the mount to face the opposite direction. Restart the engine and operate the carriage, drum, and vibrator controls to check their operation.

3-34

C-650-F/S C

!

CAUTION!

Section 28—Install the transport assembly

!

TO PREVENT DAMAGE TO THE VIBRATOR HYDRAULIC SYSTEM, COUPLE THE VIBRATOR HYDRAULIC LINES FROM THE CARRIAGE VIBRATOR VARIABLE AND OIL TANK AND TURN THE VIBRATOR VARIABLE CONTROL TO THE OFF POSITION WHENEVER THE VIBRATOR IS DISCONNECTED FROM THE CARRIAGE.

Section 27—Install the optional carriage weight 008-0445A

The transport assembly is designed to move the machine into position on the jobsite. NOTE: The transport assembly should not be used on machines wider than 36 feet (11 m). Install the transport wheel assembly no more than 10 feet (3 m) from the console end of the machine frame. To install the transport assembly, first remove a cross arm from the top of the machine frame (the cross arm should be no more than 10 feet (3 m) from the console end of the frame). Leave the sway bars in place and align the holes in the sway bars with the holes in the top of the frame. TC338

Carriage weight installed behind carriage

If options (pan vibrator, stinger vibrator, adjustable augers, etc.) are installed on the front of the carriage, a carriage weight must be added to the back of the carriage to counterbalance the extra weight out front. NOTE: If a fuel tank is mounted behind the carriage, the carriage weight can be reduced or eliminated (depending on the weight of the options installed in front of the carriage). To install the carriage weight, insert an inner mount arm tube into both outer mount arm tubes behind the carriage. Push the inner tubes into the outer tubes until the middle set of holes in the inner tubes are aligned with the set of holes in the back of the outer tubes. Insert a 1 3⁄4 inch bolt through the holes on both tube assemblies and install Nylox nuts. Tighten securely. Attach the carriage weight to the back of the inner tubes with two 6 1⁄2 inch bolts and two Nylox nuts. Tighten securely.

Transport wheel assembly post

Use a suitable lifting device to lift the transport wheel assembly over the frame. Carefully align the posts in the bottom of the transport wheel assembly cross bar with the holes in the sway bars and the top of the frame. Lower the transport assembly posts down into the frame. 008-0408

The carriage weight may have to be adjusted to correctly counterbalance the weight in front of the carriage. If the weight in front of the carriage (the pan vibrator, stinger vibrator, or adjustable augers) still pulls the carriage down in the front, add more weight or slide the rear inner tubes out until the carriage is balanced. If the carriage weight in back of the carriage pulls the carriage down in back, remove some weight or slide the rear inner tubes in until the carriage is balanced. Replace all bolts and Nylox nuts and tighten securely. Transport assembly clamp installed

3-35

C-650-F/S Insert the posts on the two transport assembly clamps up into the holes in the bottom of the frame beneath the transport assembly. Attach each transport assembly clamp to the transport assembly with two 5⁄8 x 2 inch (16 x 51 mm) bolts, lock washers, and nuts. Route the hoses along the frame over to the console and connect the quick couplers to the PTA quick couplers in the console. 008-0017B

Use a suitable lifting device to raise the towing tongue up to the bottom of the towing tongue connector. Slide the tube on the front of the towing tongue into the pipe on the bottom of the front towing tongue connector. Lift the rear towing tongue connector up to the towing tongue and slide the tube on the bottom of the connector over the tube on the rear of the towing tongue. Align the vertical tube in the connector with the top and bottom holes on the back of the idler end panel and insert a 1 inch (25 mm) pin through the end panel and the tube on the towing tongue connector. Insert a hair pin into the bottom of the connector pin. If the machine will be towed with the towing tongue, use a suitable lifting device to lower the tongue until a latch pin can be inserted through the hole in the front and rear tongue connectors and the holes in the towing tongue tube. W

! Transport wheels removed for paving

If the machine will be used for paving, the transport wheels may have to be removed so that they will not interfere with the carriage. If the transport assembly will be used to move the machine, attach each wheel to the transport assembly with eight lug nuts.

WARNING!

!

THE TOWING TONGUE MAY CAUSE INJURY IF IT FALLS. USE A SUITABLE LIFTING DEVICE AND MAKE SURE THE TONGUE IS SECURE BEFORE LIFTING OR LOWERING IT INTO POSITION. Use two 1 inch (25 mm) diameter clevis pins to attach the ends of a 38 inch (96.5 cm) turnbuckle between the top hole in the front towing tongue connector and the bracket at the end of the towing tongue. Attach another 38 inch (96.5 cm) turnbuckle between the rear

To install the transport towing tongue, the firstflanges lift the front towing tongue connector up between on the top and bottom of the idler end panel. Align the vertical tube in the connector with the top and bottom holes on the front of the idler end panel. Insert a 1 inch (25 mm) pin through the end panel flanges and the tube on the towing tongue connector. Insert a hair pin into the bottom of the connector pin.

towing connector andmm) the diameter end of theclevis towing tongue tongue using two 1 inch (25 pins. Attach hair pins to both ends of all clevis pins. Tighten both turnbuckles until they help support the weight of the towing tongue.

008-0061

DO NOT EXCEED 10 MPH (16 KM) WHEN TOWING THE MACHINE WITH THE TRANSPORT ASSEMBLY

C

!

CAUTION!

!

When not using the towing tongue, remove both 38 inch (96.5 cm) turnbuckles and use a suitable lifting device to raise the towing tongue enough so the two latch pins can be removed. Lift the tongue until a latch pin can be inserted down through the hole in the front and rear tongue connectors and the holes in the towing tongue tube. Secure the top end of the towing tongue to the top of the idler end panel with the 3⁄16 x 30 inch (.5 x 76.2 cm) chain.

Transport towing tongue installed

3-36

C-650-F/S CHAPTER IV—C-650 SETUP AND OPERATION ................................................................. 4-1 Section 01—Content of chapter ..................................................................................................................... 4-1 Section 02—Bogie running surfaces (C-650-F only) ...................................................................................... 4-1 Section 03—Adjusting the height of the drums .............................................................................................. 4-2 Section 04—Installing a drum lowering kit ...................................................................................................... 4-3 Section 05—Rigging for lifting and installing on forms or bogie rails .............................................................. 4-4 Section 06—Adjust the machine to the stringline (sensor equipped machines only) ..................................... 4-5 Section 07—Square the frame to the slab surface ......................................................................................... 4-6 Section 08—Square up the optional PTA ....................................................................................................... 4-7 Section 09—Square the ends of the carriage rails to the slab surface ........................................................... 4-9 Section 10—Stringline the carriage rails to the slab profile .......................................................................... 4-10 Section 11—Adjusting the drum(s) to final grade ......................................................................................... 4-12 Section 12—Setting up the optional adjustable augers ................................................................................ 4-15 Section 13—Setting up the optional rotary stinger vibrator .......................................................................... 4-15 Section 14—Setting up the optional pan vibrator ......................................................................................... 4-16 Section 15—Starting a pour ......................................................................................................................... 4-17 Section 16—Machine operation and finishing procedures ........................................................................... 4-18 Section 17—Finish troubleshooting .............................................................................................................. 4-21 Section 18—Estimating the rate of pour and concrete usage ...................................................................... 4-22

C-650-F/S

C-650-F/S 034-0185

CHAPTER IV—SETUP AND OPERATION Section 01—Content of chapter This chapter contains instructions for adjusting the C-650 to meet jobsite specifications. These instructions are recommended procedures only. Read this chapter thoroughly to identify yourself with your particular machine setup. Pay Particular Attention to all Safety Statements.

Before using a C-650-F on any surface, weigh the machine to make sure it can be supported. Even when rails or slab forms do not collapse under the load of a machine, inadequate forms, rail, or jacks may sag, causing dips in the concrete.

Section 02—Bogie running surfaces (C-650-F only) C

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CAUTION!

Form failure

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TO PREVENT INJURY AND DAMAGE TO LIFTING EQUIPMENT AND MACHINE RUNNING SURFACES, MACHINE OWNERS SHOULD WEIGH THEIR OWN MACHINES BEFORE LIFTING THEM OR OPERATING THEM ON UNTESTED SUPPORT SYSTEMS (RAILS, FORMS, BRIDGES, ETC.). The C-650-F bogies may be operated on flat surfaces (such as existing pavement), directly on top of certain slab forms, or on a variety of rail systems. The bogies can run on GOMACO Manufactured rail systems using either 2 x 2 inch (51 x 51 mm) square rail (3⁄16 inch (5 mm) walls), 2 inch (51 mm) ID standard pipe rail (schedule 40), or 2 inch (51 mm) ID heavy pipe rail (schedule 80) set on height-adjustable jack mounts. The bogies may also be set directly on top of slab forms for slab paving, or on 2 x 2 inch (51 x 51 mm) square rail laid directly in the gutter of curb and gutter for street paving.

Before using rail systems, determine the number of rail jacks that must be placed under the rails. First, move the carriage to the end of the machine opposite the console and weigh it. Then move the carriage to the console end of the machine and weigh the console end. Take the weight of the heaviest end of the machine and divide by four to find the wheel load weight. For example, if the heaviest end of the machine weighs 6112 lbs. (2772 kg) the maximum wheel load weight of the machine is 6112 ÷ 4 = 1528 lbs. (2772 ÷ 4 = 693 kg). Compare the machine’s maximum wheel load weight to the maximum allowable weights in the “GOMACO Rail Wheel Load Table” below to determine which GOMACO rail system and jack spacing to use. For example, if the machine’s maximum wheel load weight is 1528 lbs. (693 kg), the minimum rail system that can be used is 2 inch (51 mm) heavy pipe (schedule 80) with the rail jacks spaced a maximum of 36 inches (914 cm) apart (any lighter rail system or wider jack spacing would not support the machine adequately).

GOMACO manufactured rail systems and rail supports are available in 12 foot (3.66 M) sections with connectors welded into one end. Height adjustable jack mounts are designed to match the type of rail used, and may be mounted directly on the curb form, either on top or through the slab forms.

C

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CAUTION!

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A RAIL SUPPORT JACK MUST BE PLACED UNDER EACH JOINT IN THE RAIL TO SUPPORT THE CONNECTION.

4-1

C-650-F/S 034-0189

W

Maximum jack spacing 24 inches 36 inches (61.9 cm) (91.4 cm) inch m 2(5.08 cm) te STD Pipe s ID(Schd 40) y s li 2 x 2 inch a r (5.08 x 5.08 cm) O

SQ Tube

(3/16 inch (48 mm) wall)

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2020 lbs 1232 lbs 519 lbs (916 kg)

(559 kg)

(235 kg)

(1091 kg)

(561 kg)

(236 kg)

1606 lbs 677 lbs (728 kg)

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To adjust the carriage wheel height after the carriage is installed in the machine frame, first remove the four keeper rollers from under the carriage rail. Place enough blocking under the undercarriage to safely support the total weight of the carriage and undercarriage. Use the grade jacks to lower the machine frame until the carriage is safely supported on the blocking.

2405 lbs 1236 lbs 521 lbs

A C M 2 inch 2632 lbs (5.08 cm) O ID Heavy Pipe (1194 kg) G (Sched 80)

WARNING!

TO PREVENT CRUSHING INJURIES OR DEATH, MAKE SURE THE BLOCKING WILL SAFELY SUPPORT THE WEIGHT OF THE CARRIAGE AND UNDERCARRIAGE WITHOUT COLLAPSING OR OVERTURNING BEFORE IT SUPPORTS THE WEIGHT OF THE CARRIAGE.

48 inches (121.9 cm)

(307 kg) 034-0189

GOMACO Rail Wheel Load Table

Remove and reinstall the carriage wheels on the top set of holes to lower the carriage and drum(s) 6 inches (15.2 cm). Remove and reinstall the carriage wheels on the bottom set of holes to raise the carriage and drum(s) 6 inches (15.2 cm).

Section 03—Adjusting the height of the drums Notice: The bogie rails must be set exactly to their final grade before the machine can be adjusted to its final grade.

Use the grade jacks to raise the frame until the carriage wheels and the carriage are supported by the carriage rails. Remove the blocking and reinstall the four keeper rollers.

If the drum(s) are too high or too low to reach the surface of the slab even if the grade jacks are raised or lowered all the way, the carriage wheels and/or the grade jack mounts can be adjusted up or down.

ADJUSTING THE JACK MOUNT HEIGHT: W

If the when drum(s) not are reach the surface the slab even thewill jacks mounted in theofhighest position and the carriage is completely lowered, special drum lowering kits can be purchased from GOMACO and installed. Available kits can lower single- or double-drum undercarriages 12 inches (30.5 cm), 18 inches (45.7 cm), 24 inches (61 cm), or 32 inches (81.3 cm). A 36 inch (91.4 cm) lowering kit is also available for double-drum undercarriages only. See Section 04—Installing a drum lowering kitfor installation instructions.

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WARNING!

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TO PREVENT INJURY OR DEATH, USE ADEQUATE BLOCKING UNDER THE FRAME WHEN MAKING THESE ADJUSTMENTS. USE CAUTION WHEN LIFTING THE GRADE JACKS. To raise or lower the grade jacks, block the frame of the machine solidly before each grade jack is changed. Use a suitable lifting device to support the jack and keep it from falling when the bolts are removed. Raise or lower the jack slightly until the bolts holding the grade jack to the mount are loose.

ADJUSTING THE CARRIAGE WHEEL HEIGHT: The carriage wheel height can be easily adjusted when the carriage is not installed in the machine frame. Simply remove the carriage wheels and keeper rollers and reinstall them in the high or low position.

Remove the bolts and raise or lower the jack to the correct height. To raise the frame and drum(s), lower the grade jacks on the mounts. To lower the frame and drum(s), raise the jacks on the mounts. Raising or lowering the jacks one hole in the mounts moves the drum(s) up or down 4 inches (10.2 cm). Notice: To prevent damage to the grade jacks and mounts, do not lower the jacks more than 2 holes or 8 inches (20.3 cm) below the bottom of the jack mounts. Do not raise the jacks higher thanthree holes up from the bottom of the jack mounts.

4-2

C-650-F/S When the jacks are at the correct height, reinstall the bolts and tighten the nutssecurely. Remove the blocking from under the frame.

float pan hanger hole on the front and rear of the undercarriage. Tighten both nuts securely.

Section 04—Installing a drum lowering kit 008-0029

Use a 3⁄8 inch (10 mm) bolt, flat washer (on the slottedhole side), lock washer, and nut to attach the angle brace to the top hole on the rear extension (formerly the top chain guard bolt hole). Use another 3⁄8 inch (10 mm) bolt, flat washer (on the slotted-hole side), lock washer, and nut to attach the other end of the angle brace to the front drum extension (at the small hole just above the right set of front bearing bolt holes). Tighten both nuts securely. Reinstall the drum at the bottom of the drum extensions. Attach a drive chain extension to the drive chain and reinstall the drive chain. Readjust the chain tension according to directions in Chapter V, Section 05—10 hour or daily Service. INSTALLING A DOUBLE-DRUM LOWERING KIT: To install a double-drum lowering kit, first reverse the directions in Chapter III, Section 15—Install the undercarriage to remove the undercarriage from the carriage. When the undercarriage is off the machine, use a lifting device to turn it over so the drums are on top.

Double drum lowering kit installed

If the drum(s) are not low enough to reach the surface of the slab even when the carriage is lowered all the way and the jacks are raised as high as possible in their mounts, special drum lowering kits can be purchased from GOMACO and installed. Available kits can lower single- or double-drum undercarriages 12 inches (30.5 cm), 18 inches (45.7 cm), 24 inches (61 cm), or 32 inches (81.3 cm). A 36 INCH (91.4 cm) lowering kit is also available for double-drum

Disconnect the connecting links of both drum drive chains and remove the chains. Loosen the setscrews in the drive sprockets and remove the sprockets from the drive motor shafts. Remove the 1⁄2 inch (13 mm) bolts that hold the drive motors to the undercarriage and remove the drive motors (leave the hoses attached).

undercarriages only. NOTE: the procedure for installing a drum lowering kit on a single-drum undercarriage is different from the procedure for installing a kit on a double-drum undercarriage. Follow the appropriate directions below.

Remove the four 1⁄2 (13 mm) bolts holding the front and rear bearings of the stationary drums in the undercarriage and remove the stationary drum. Remove the 1⁄2 x 1 3⁄4 inch (13 x 45 mm) bolts from the eccentric cams on the front and rear of the adjustable drum and remove the drum from the undercarriage.

INSTALLING A SINGLE-DRUM LOWERING KIT: To install a drum lowering kit on single-drum undercarriage, first remove the float pan, float pan rod, and chain guard from the undercarriage. Disconnect the chain connecting link from the drum chain and remove the drum chain. Remove the four 1⁄2 x 1 1⁄2 inch (13 x 38 mm) bolts holding each of the two drum bearings to the undercarriage and remove the drum.

Reverse the directions above to reinstall the undercarriage components in the lowering kit undercarriage frame. Tighten all bolts securely and follow the directions in Chapter III, Section 15— Install the undercarriage to install the undercarriage onto the carriage.

Attach a drum extension to the front and rear of the undercarriage frame using four 1⁄2 inch (13 mm) bolts, flat washers (on the slotted-hole side), lock washers, 1

and nuts on each extension (the ⁄2 inch (13 mm) bolts are installed through the bolt holes that held the drum bearings to the undercarriage frame). Tighten all nuts securely. Install a 3⁄8 inch (10 mm) bolt, flat washer (on the slotted-hole side), lock washer, and nut through the

4-3

C-650-F/S The self- and power-widening jacks may also be used to balance the machine (C-650-F only). When the self- or power-widening jacks are in the proper position, tighten the locking screws on the self- or power-widening jack mounts to prevent them from moving.

Section 05—Rigging for lifting and installing on forms or bogie rails W

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WARNING!

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FAILURE TO FOLLOW THE RECOMMENDATIONS IN THIS SECTION WILL RESULT IN DAMAGE TO THE MACHINE OR SEVERE INJURY TO PERSONNEL INVOLVED IN THE LIFTING OF THE C-650-F/S.

Notice: To prevent damage to the machine and bogie rails or slab forms, loosen the locking screws on the self- or power-widening jack mounts before moving the power-widening jacks or paving a variable-width slab (C-650-F only).

DO NOT GET UNDER THE C-650-F/S WHEN IT IS BEING LIFTED. THE C-650-F/S CAN CAUSE SERIOUS INJURY OR DEATH IF IT FALLS.

If the machine is equipped with slope jack mount adapters and is being used to finish a slope, remove the locking bolts and rotate the mounts to the correct angle while the machine is lifted slightly off the ground. Securely bolt the mounts in the correct position before lifting the machine over the bogie rails or slab forms

KEEP ALL LIFTING EQUIPMENT CLEAR OF OVERHEAD ELECTRIC POWER WIRES. SEVERE ELECTRICAL SHOCK CAN OCCUR IF CONTACT IS MADE WITH ELECTRICAL POWER WIRES.

009-0018

TO PREVENT INJURY AND DAMAGE TO LIFTING EQUIPMENT AND MACHINE RUNNING SURFACES, WEIGH THE - BEFORE LIFTING IT OR OPERATING IT ON UNTESTED SUPPORT SYSTEMS (RAILS, FORMS, BRIDGES, ETC.). Notice: The top of the C-650-F/S frame must be under compression during lifting—always place lifting straps to the outside of the last frame joints on the left and right sides of the machine. Consult a rigging and lifting specialist with any questions about rigging before lifting the C-650-F/S. 016-0086

Slope jack mount adapter bolted at slope angle

NOTE: To prevent damage to the bogies, jacks, and jack mounts, do not set the machine on a flat surface unless slope jack mount adapters are securely bolted in the vertical position.

TWO POINT BRIDLE

016-0086

If the machine is being used to finish a slope and is equipped with slope console mounts, tilt the mounts so that the console is level when the machine is in place on the slope. Bolt the mounts securely in position.

Rigging for lifting

The C-650-F/S may have to be lifted onto the running rails or job site. Care and reasonable judgement must be used before the C-650-F/S is lifted. Be certain that the center of the machine supports the majority of the load to avoid midair cantilevering.

C

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CAUTION!

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TO PREVENT OIL STARVATION AND ENGINE DAMAGE, MAKE SURE THE ENGINE ON SLOPE MACHINES IS AS CLOSE TO LEVEL AS POSSIBLE

Before lifting, recheck the bolts and pins between all frame sections. Move the carriage to the left or right in the frame to balance the C-650-F/S before lifting. When the carriage is in the proper position, secure it to the carriage rail before the machine is lifted to prevent the carriage from moving.

DURING OPERATION.

4-4

C-650-F/S securely). Adjust the rear steering sensor in the same manner.

Section 06—Adjust the machine to the stringline (sensor equipped machines only)

Place the key switch in the “on” position and place the steer on/off switch in the “on” position. Place the auto steer switch in the “forward” position.

ALIGN THE MACHINE TO THE STRINGLINE Move the machine into position along the stringline. Steer the machine left or right until it is approximately parallel to the stringlines and the insides of the slipforms are approximately the correct distance from the stringline.

Place the on/off switch on the front steer sensor in the “on” position. Adjust the front steering sensor jack in or out until both indicator lights on the sensor are off.

Use the grade jog switches to manually raise or lower the front and rear of the right and left sides of the machine until the machine frame near the height it will be during paving operations and is approximately parallel to the stringline.

If the machine is equipped with a rear steer sensor, place the auto steer switch in the “reverse” position and place the on/off switch on the rear steering sensor in the “on” position. Adjust the rear steering sensor jack in or out until both indicator lights on the sensor are off.

ADJUST THE STEERING SENSORS TO THE STRINGLINE

ADJUST THE GRADE SENSORS TO THE STRINGLINE

047-3115

047-3116

Adjust Grade Sensors to Line

Use the following procedure to adjust all four grade sensors to the stringline. To allow grade adjustments after the machine is set to line, turn the grade adjustment jack up or down until approximately 6 inch (15 cm) of jack is exposed before making sensor adjustments. Place the grade wands under the stringline. Adjust the grade sensor jack until the grade jack wand is parallel to the stringline (if a large amount of adjustment is needed, loosen the setscrews in the grade sensor jack brackets and raise or lower the jacks as needed until the wand is parallel to the stringline). Loosen the clamp bolt in the grade jack bracket and slide the jack left or right until the stringline is centered on the grade wand.

Adjust the steering sensors to line

To allow steering adjustments after the machine is set to line, turn the steering adjustment jack in the end of the sensor arm assembly in or out until approximately 6 inch (15 cm) of jack is exposed. Place the front steering wand against the stringline. Loosen the setscrew in the steering sensor square tube mount and adjust the sensor assembly up or down until the stringline is operating on the lower 1⁄3 of the sensor wand. Adjust the sensor in or out until the wand is perpendicular to the stringline (if a large amount of lateral sensor adjustment is needed, loosen the setscrews on the pivot mount and adjust the sensor arm assembly in or out and tighten the setscrews

Place the ignition switch in the “on” position and place the grade sensor on/off switches in the “on” position. Place the on/off switches on the grade sensors in the “on” position. Adjust each grade sensor up or down

4-5

C-650-F/S with the grade jack until the indicator lights on the sensors are off.

measurement (1 turn of the grade jack handle equals approximately 1⁄8 inch (3 mm) of adjustment).

W

Repeat the procedure to align the left front grade sensor to the left rear grade sensor. Adjust the two left grade sensor jacks together until they match the right grade sensors. After the machine is parallel to the stringline and the surface of the slab to be poured, make any grade adjustments to all four grade sensor jacks equally.

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WARNING!

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SEVERE INJURY CAN OCCUR TO ANYONE ON OR AROUND THE MACHINE IF THEY ARE CAUGHT IN ANY MOVING PARTS. MAKE SURE EVERYONE IS CLEAR OF THE MACHINE BEFORE THE ENGINE IS STARTED. Start the engine and place all sensor switches in the

Section 07—Square the frame to the slab

“on” position. Place the auto steer switch in the “forward” position. Move the machine forward 20 to 30 ft. (6 to 9 M).

034-0038A

surface

Measure the distance between the inside of the slipform and the stringline. If the distance is incorrect, turn the steering sensor jack to move the sensor away from the machine (to increase the distance) or towards the machine (to decrease the distance). One turn of the steering jack handle equals approximately 1⁄8 inch (3 mm) of adjustment. 047-3117

Tighten the locking screws on self- or power-widening jack mounts

If the machine is a forms C-650-F, the machine on the bogie rails or slab andplace securely tighten the locking screws on self- or power-widening jack mounts to lock the self-widening jacks and bogies in place. If the machine is a C-650-S, follow the procedures in the previous section to position the machine parallel to the stringline above the slab to be poured. W

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WARNING!

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TO PREVENT SERIOUS INJURY, KEEP HANDS AND FEET CLEAR OF THE CARRIAGE RAILS, CARRIAGE CHAINS, AND THE BOGIE RAILS WHILE MOVING THE CARRIAGE OR BOGIES.

Adjust grade sensor

Hold a straight edge under the right front of the machine frame and extend it over the stringline. Measure the distance between the straight edge and the stringline and note the measurement.

Move the carriage to the center of the C-650 to compensate for any machine frame deflection. If any extra weight will be on the machine frame during the pour (generators, vibrators, water tanks, etc.), make sure they are in place during adjustment procedures. If the console is located near the center of the frame, make sure a weight equal to that of the operator is placed on or near the console during adjustment procedures.

Hold a straight edge under the right rear of the machine frame and extend it over the stringline. Measure the distance between the straight edge and the stringline. If the distance between the right rear of the frame and the stringline is not within 1⁄8 inch (3 mm) of the right front measurement, adjust the machine up or down with the grade sensor jack and recheck the

4-6

C-650-F/S 008-0062

NOTE: If the machine is a C-650-F, loosen the locking screws on self- or power-widening jack mounts before moving the power-widening jacks or paving a variable-width slab to prevent damage to the machine and bogie rails or slab forms. 008-0204

Lock the grade jacks in place

If the machine is a C-650-F, insert the 3⁄8 inch (10 mm) pins into the horizontal or vertical holes (whichever line up) to lock the grade jacks into place when all four corners of the machine are the same distance above the surface of the slab.

Section 08—Square up the optional PTA 016-0039A

Measure from the machine frame to the slab surface

Set the corners of the frame so that they are all the same distance above the surface of the concrete to be poured: measure from the same spot near each grade jack on the bottom of the frame to the top of the slab surface. Use the grade jacks to adjust the machine frame up or down until all four corners of the frame are the same distance above the surface of the concrete to be poured. If the machine is equipped with a PTA, the front and rear PTA turnbuckles must be extended exactly the same distance so that the front and rear of the PTA are the same distance above the surface of the concrete.

For example, if the surface of the slab to be poured will be flush with the top of the left and right slab forms, all four corners of the machine can be the same distance above the top of the slab forms. If the left and right bogie rails or slab forms are at different elevations from each other or the slab surface, or if the machine is being used to pour a slope, all four corners of the machine must be the same distance from the surface of the slab to be poured.

NOTE: If the frame is over 50 feet (15.2 M) wide, use a laser or transit in place of a stringline to straighten the frame (to eliminate stringline deflection).

4-7

C-650-F/S 008-0402

034-0190

Stringline Spacer blocks

008-0402

Stringline the frame

Tie one end of a stringline to the rear of an end panel Remove the PTA access panels

so that the string is aligned with the rear of the frame. Unroll the stringline along the rear of the frame under its entire width. Stretch the string as tight as possible and tie it to the console end panel. Use two spacers and tie another tight stringline along the front of the frame in the same manner.

If the two measurements are not the same, remove the access panels on the PTA. Note how much the drive chain deflects between the sprockets. Loosen and remove the drive chain from the screw adjuster sprockets.

Locate four small blocks of wood or four nuts of equal thickness to act as spacers. Place a spacer between the frame and the stringline at each of the four spots near the jacks where the distance between the frame and the slab surface was measured.

016-0039A

008-0368

PTA screw adjusters

Turn the barrel of the front or rear screw adjuster to raise or lower the front or rear of the PTA until the two stringline-to-frame measurements are equal. Reinstall the drive chain around the sprockets and tighten the chain until it the deflection between the sprockets is the same as that noted earlier. Replace the access panels on the PTA.

Measure from the stringline to the PTA frame joints

Measure from the rear stringline up to the rear joint in the machine frame under the PTA. Measure from the front stringline up to the front joint in the machine frame under the PTA.

Use the fifth spacer to check the stringline-to-frame measurement on the front and rear PTA joint. If the spacer just fits between the stringline and the frame, the PTA is set flat with the frame. If there is too much or too little space between the stringline and the frame at the PTA, raise or lower the PTA: make sure the quick couplers from the PTA drive motor are connected to the “PTA” quick couplers on the console. Place all controls in the “neutral” or off position, pull out all E-Stop buttons, and start the engine. Reset the E-Stop system, make sure the travel directional control is in the “neutral” position, and place the PTA control lever on the console in the “up”

4-8

C-650-F/S 008-0231

or “down” position to raise or lower the PTA. Slowly rotate the bogie travel variable control in the “increase” direction to slowly raise or lower the PTA until the stringline spacer just fits between the stringline and the frame under the PTA. Turn the bogie travel variable control to the “off ” position and place the PTA control valve in the “neutral” position to stop moving the PTA up or down. Place all controls in the “neutral” or “off” position and shut off the engine. When the spacer just fits between the stringline and the frame at the PTA, the PTA is set flat, and the frame is flat from one side to the other. 034-0171

Loosen carriage rail bolts

To adjust the rail, first adjust the four corners of the rail: loosen all of the 11⁄16 inch (17 mm) nuts holding the carriage rail in place along the front and rear of the machine frame. 034-0049

PTA indicator (1 of 2)

If either of the PTA indicators do not point straight up when the PTA is in the “flat” position, loosen the U-bolt under the indicator and turn the indicator until it points straight up.

Section 09—Square the ends of the carriage rails to the slab surface

Measure from form to bottom of carriage rail

All four corners of the carriage rail next to the grade jacks must be the same distance from the surface of the concrete to be poured (for example, if the surface of the slab to be poured will be flush with the top of the left and right slab forms, all four corners of the carriage rail should be the same distance above the top of the slab forms). Measure from the slab surface to the bottom of the carriage rails.

The time spent correctly adjusting the carriage rail adjustment is well worth the efficiency and product quality gained—the profile of the carriage rails bolted to the inside the C-650-F/S frame determines the profile of the slab to be finished. Both the front and rear carriage rails must have exactly the same profile to keep the carriage and drum(s) parallel to the surface of the concrete. Notice: If the carriage rail is not properly adjusted, the final grade and finish of the concrete will not be satisfactory.

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C-650-F/S 008-0184A

SETTING THE CARRIAGE RAILS FORA FLAT SLAB (WITH OR WITHOUT A PTA): NOTE: If the frame is equipped with a PTA, follow the directions in Section 08—Square up the optional PTA before stringlining the rails. 008-0419

Stringline

Adjust carriage rail bolts

008-0193

Spacers

008-0419

Use a 3⁄4 inch (19 mm) wrench to adjust the corners of the carriage rail up or down until all four corners of the carriage rail are the same distance above the surface of the concrete to be poured (the brackets next to the corner brackets may also have to be adjusted up or down before the corner brackets are adjusted). 034-0192A

Stringline the carriage rail

To set the rails for a flat slab, first tie one end of a stringline to one end panel and align the string with the rear carriage rail. Unroll the stringline across the entire width of the C-650. Tie the stringline to the opposite end panel after stretching the stringline as tight as possible. Align the string with the carriage rail and place it under the rail. 008-0194

11

⁄16 inch (18 mm) rail locking nuts

Tighten the 11⁄16 inch (18 mm) rail locking nuts above the spots on the rails that were just measured. Recheck the slab-to-rail distances and readjust as necessary.

Section 10—Stringline the carriage rails to the slab profile When the ends of the rails are set correctly, follow the directions in one of the sections below to set the carriage rail to the correct profile NOTE: If the frame is over 50 feet (15.2 M) wide, use a laser or transit in place of a stringline to straighten the carriage rail (to eliminate stringline deflection).

Stringline spacer (1 of 3) Locate three small blocks of wood or three nuts of equal thickness to act as spacers. Place a spacer between the rail and the stringline on each end of the rear carriage rail (place the spacer directly under the spots where the distance between the carriage rail and

4-10

C-650-F/S the bogie rails was measured previously). Install a stringline under the front carriage rail in the same manner.

If slab will have a crown and the machine is equipped with a PTA, first follow the directions in the “Setting the carriage rails for a flat slab (with or without a PTA)” section above to set the rails flat along the entire width of the frame. Then measure from the front stringline to the bottom of the carriage rail (be sure to allow for the width of the spacers at each end of the stringline). Hold the PTA valve in the “up” position until the correct crown is achieved.

008-0266

Measure from the slab grade up to the front and rear of the frame. If the distance to the rear frame is not the same as the distance to the front frame, repeat the procedures in Section 08 Square up the optional PTA to check and square up the PTA. —

SETTING THE CARRIAGE RAILS FOR AN INVERT (PTA-EQUIPPED MACHINES): 008-0404

Spacer between rail and stringline

Use the third spacer to check the distance between the stringline and the rail. Start at one side of the machine and adjust the rail up or down with the rail adjustment bolts until the spacer just touches the rail and the stringline.

PTA Carriage rail sections 008-0404

NOTE: If a bolt cannot be raised or lowered far enough, the 2 or 3 bolts on either side of the bolt being adjusted may also have to be raised or lowered.

Carriage rails set for invert

Tighten the carriage rail bolt locking nuts securely after each bracket is adjusted. Recheck the rail-to-string measurement after tightening. When all the brackets on the rear carriage rail have been adjusted and tightened, sight down along the entire length of the rail to make sure it is straight. Make any final adjustments as necessary and repeat the procedures above to stringline the front carriage rail.

When the carriage rail is set flat, watch the PTA indicators and hold the PTA valve in the “down” position until the PTA indicators have turned the same number of turns as before. The carriage rails should now contain the same invert as the slab.

SETTING THE CARRIAGE RAILS FOR A CROWNED SLAB (PTA-EQUIPPED MACHINES): 008-0403

PTA

Measure from the slab grade up to the front and rear of the frame. If the distance to the rear frame is not the same as the distance to the front frame, repeat the procedures in Section 08—Square up the optional PTA to check and square up the PTA.

Carriage rail sections

Stringline Spacers

If the slab will contain an invert, first measure up from the stringline under the carriage rail and raise the PTA until the carriage rail at the PTA is the same distance above flat that the invert will go down (be sure to allow for the width of the spacers at the end of the carriage rails). Count the number of rotations that the indicators make while raising the PTA so it can be lowered the same amount later. Then follow the directions in the “Setting the carriage rails for a flat slab (with or without a PTA)” section above to set the carriage rails flat (the PTA will be lowered later to create the invert).

008-0403

Carriage rails set for a crown (PTA equipped machines)

SETTING THE CARRIAGE RAILS FOR A CROWN WITHOUT A PTA: NOTE: If possible, assemble the machine with a pin-connected joint over the crown point to ease setting the crown in the carriage rails.

4-11

C-650-F/S If a crown is required but the machine is not equipped with a PTA, the crown must be set into the carriage rails. First, follow the directions in the “Setting the ” carriage rails for a flat slab (with or without a PTA) section above to set up a stringline under the rear carriage rail. Next, find the crown point on the rear carriage rail. Measure from the stringline to the crown point on the carriage rail and adjust the carriage rail up at the crown point with the adjusting bolts until the correct crown is achieved (be sure to allow for the spacer thickness when measuring the crown). Securely tighten the locking nuts above the crown point.

just touches the rail and the stringline. Tighten the carriage rail bolt locking nuts securely after each bracket is adjusted. Recheck the rail-to-string measurement after tightening. When all the brackets have been adjusted and tightened, sight down along each half of the rails to make sure they are straight. Make final adjustments as necessary. Leave the stringlines in place and remove the spacers from the crown points. Retighten the stringlines and measure from the front and rear crown points to the stringlines to recheck the amount of crown. Readjust as necessary.

008-0266

Section 11—Adjusting the drum(s) to final grade After the carriage rail has been properly adjusted, the bottom of the drum(s) must be set to the final slab height. 008-0350A

Spacer between rail and stringline

When the crown point is set in the left and right carriage rails, adjust the middle of the carriage rails up or down so that they roughly follows a straight line between the crown point and the ends of the frame (make sure the crown point and the end points of the rail do not move). Stringline stretched tight across slab forms for horizontal slab

008-0405

Carriage rail sections

If the side forms or slip forms will determine the final height of the slab, stretch a stringline tight across the top of the forms (the forms must be set to proper grade throughout the length of the slab).

Stringline

Spacers

008-0405

C

Stringlining carriage rails for a crown without a PTA

Place another spacer at the crown point and fasten the stringline to the spacer. Repeat the procedure above to put a crown in the front carriage rail. Now there is a straight stringline from the crown point to each end of the carriage rails that can be used to precisely straighten the front and rear rails. Use another spacer of equal thickness to check the stringline-to-rail distance between the ends of the rails. Start at one side of the machine and adjust the rail up or down with the rail adjustment bolts until the spacer

!

CAUTION!

!

IF MACHINE WILL RUN ON SLAB FORMS OR RAILS, AND THE FORMS OR RAILS ARE NOT PROPERLY ADJUSTED, THE FINAL GRADE OF THE CONCRETE WILL NOT BE SATISFACTORY.

4-12

C-650-F/S 009-0022A

008-0259

Slope stringline set for the top of the slab

Rear of drum over stringline

If the height of the slab will be different than the height of the forms, or if the machine will be used to finish a slope, stretch a stringline between two stakes at the same height as the final slab. The stringline must be set to the correct slab height before the drum can be set correctly.

Move the carriage to the console end of the machine. Move the machine forward or backward until the back of the drum is directly over the stringline (if the machine is equipped with a double-drum undercarriage, make sure the rear of the fixed drum is over the stringline). Check the distance between the bottom of the finishing drum and the stringline.

008-0211A

Adjust the rear grade jack or grade sensor jack on the console end up or down until the rear of the finishing drum just touches the stringline (if the machine is equipped with a double-drum undercarriage, make sure the rear of the fixed drum just touches the stringline). 008-0062

Raise the adjustable drum

If the machine is equipped with a double-drum undercarriage, loosen the adjustable drum locking nuts on the front and rear of the undercarriage and turn the front and rear adjusting cams to raise the adjustable drum as high as it will go. Securely tighten the two locking nuts. W

!

WARNING!

!

TO PREVENT SERIOUS INJURY, KEEP HANDS AND FEET CLEAR OF THE CARRIAGE RAILS, CARRIAGE CHAINS, AND THE BOGIE RAILS WHILE MOVING THE CARRIAGE.

Grade jack locking pin

If the machine is a C-650-F, replace the locking pin in the rear grade jack.

4-13

C-650-F/S 008-0237A

NOTE: If the machine is equipped with double drums and will be used to finish a slope, leave the adjustable drum raised as high as possible (only one drum is needed to finish a slope). 008-0200A

Front of drum over stringline

Move the machine backwards until the front of the finishing drum is directly over the stringline (if the machine is equipped with a double-drum undercarriage, make sure the front of the fixed drum is over the stringline). Check the distance between the bottom of the finishing drum and the stringline. Adjust the front grade jack or grade sensor jack on the console end up or down until the front of the finishing drum just touches the stringline.

Lower the adjustable drum to the stringline

If the machine is a C-650-F, replace the locking pin in the rear grade jack.

Loosen the rear adjustable drum locking nut and turn the adjusting cam to lower the adjustable drum until it just touches the stringline (the front of the adjustable drum may have to be lowered part way first). Securely tighten the locking nut.

Move the machine forward again until the rear of the drum is directly over the stringline and recheck and adjust the rear jack or grade sensor jack on the console end (raising or lowering the front of the machine also slightly raises or lowers the rear). When

When the rear of the adjustable drum is set to the stringline, back up the machine until the front of the adjustable drum is directly over the stringline. Loosen the front locking nut and adjust the drum to the stringline. Move the machine forward again and

the rear of the drum has been checked and readjusted, back up the machine and recheck the front of the drum at the console end.

recheck the rear of the adjustable drum. Readjust as necessary.

Move the carriage to the opposite end of the machine and repeat the entire procedure above to adjust the drum(s) to the stringline.

Move the carriage to the opposite end of the machine and recheck the alignment of the adjustable drum. Readjust and repeat the procedure as necessary. NOTE: If the adjustable drum is not set correctly according to the directions above, each drum will cut the concrete to a different grade when the carriage moves left and right across the slab.

Move the carriage back to the console end of the machine and repeat the entire procedure again (raising or lowering one side of the machine also slightly raises or lowers the opposite end).

034-0314

If the machine is a C-650-F, replace all the locking pins in the grade jacks when the drums are set correctly. NOTE: The time spent carefully making these adjustments will greatly improve the quality of the finished slab. If the machine is equipped with a double-drum undercarriage, return the carriage to the console side of the frame and move the machine forward or backward to position the rear of the adjustable drum directly over the stringline.

REAR

DESIRED GRADE

SUBGRADE

FRONT

DESIRED GRADE MINUS 1/8"

034-0314

If the machine is equipped with a single or doubledrum undercarriage, turn both front grade jack handles exactly one full turn to lower the front of the machine

4-14

C-650-F/S after the finishing drum(s) have been adjusted to grade as described.

079-0125A

If the machine is a C-650-F, replace the locking pins in the rear grade jacks. If the drums have been adjusted correctly to grade according to the directions above, the rear grade jacks should not have to be readjusted during the pour— unless the height of the slab forms has been set incorrectly. After the pour has started, adjust the front of the machine as necessary to obtain the required finish. NOTE: One full turn of the grade jacks equals 1⁄8 inch (3 mm). When adjusting the grade jacks up or down, rotate the jack handle one turn (or part of one turn), then finish several feet (at least 1.5 M) of slab to determine the effect of the adjustment before rotating the jack handle again.

Section 12—Setting up the optional adjustable augers

Loosen the lock nuts and turn the cams on either side of the adjustable auger to adjust the angle of the adjustable auger until all bottom edges of the augers just touch the straight edge. When the angle of the augers is adjusted correctly, tighten the locknuts securely.

If the carriage is equipped with adjustable augers, they must be set parallel and even with the bottom of the drums.

Section 13—Setting up the optional rotary stinger vibrator 016-0037A

034-0315

REAR

FRONT

STRAIGHT EDGE FROM DRUM DESIRED GRADE

DESIRED GRADE MINUS 1/8"

SUBGRADE

TO BOTTOM OF AUGER

034-0315

Align adjustable augers with the bottom of the drum(s) (turnbuckle-adjusted auger assembly shown).

First, hold a straight edge along the bottom of the drums and extend it out below the augers. Adjust the adjustable auger up or down until the back of the augers just touches the straight edge.

Rotary stinger vibrator

If the carriage is equipped with a rotary vibrator, place all controls and switches on the carriage and the console in the “off ” or “neutral” position and make sure everyone is clear of the machine. Start the engine and reset the E-Stop system. Place the carriage travel valve in the “on” position.

4-15

C-650-F/S W

016-0031

!

WARNING!

!

SEVERE INJURY CAN OCCUR TO PERSONNEL ON OR AROUND THE MACHINE IF THEY ARE CAUGHT IN ANY MOVING PARTS WHEN THE ENGINE IS STARTED. MAKE CERTAINALL PERSONNEL ARE CLEAR OF THE MACHINE BEFORE THE ENGINE IS STARTED. C

!

CAUTION!

!

TO PREVENT ENGINE DAMAGE, CHECK THE ENGINE OIL LEVEL BEFORE STARTING THE ENGINE. 016-0062B

Rotary stinger vibrator positioned above steel in slab

If the slab will contain steel, adjust the vibrator until it is as close to the center of the slab as possible and at least 1 inch (25 mm) above the steel. The vibrator cylinder can move the vibrator a total of 12 inches (30 cm). If the cylinder will not move up or down far enough, the lower guide tube that the vibrator is attached to is also manually adjustable up to 8 1⁄4 inches (21 cm) for a total of 20 1⁄4 inches (51 cm) of manual and hydraulic adjustment.

Vibrator up/down switch on console

Use the vibrator “up/down” switch (on the carriage or the console) to adjust the vibrator up or down to the correct height.

To adjust the lower guide tube, remove the 1⁄2 inch (13 mm) bolt from the top of the tube and raise or lower the tube to the next set of holes required. Insert the 1⁄2 inch (13 mm) bolt and tighten securely.

Section 14—Setting up the optional pan vibrator 016-0001A

If the concrete slab will not contain reinforcing steel, adjust the vibrator until it is in the middle of the slab depth. For example, if the slab is 12 inches (30 cm) deep, then the center of the vibrator tube would be lowered to about 6 inches (15 cm) from the bottom of the slab.

Pan vibrator at work

The bottom of the optional pan vibrator can be equipped with a fin to help consolidate concrete below the surface of the slab. If the steel in the slab is deep enough for a fin to pass over it, use a vibrator pan with a fin (available from GOMACO). If the steel in the slab is too close to the surface or if the material being vibrated will not accept a fin, the fin

4-16

C-650-F/S W

can be removed, or an additional vibrator pan without a fin can be purchased from GOMACO.

!

To correctly consolidate the concrete, the flat bottom surface of the vibrator pan must float on the slab surface. If the pan is forced down into the slab, the pan may strike off the concrete before the drum(s) can finish it. If the pan is pulled up too high, the pan will not effectively vibrate the concrete.

WARNING!

!

TO PREVENT SERIOUS INJURY, KEEP HANDS AND FEET CLEAR OF THE CARRIAGE RAILS, CARRIAGE CHAINS, AND THE BOGIE RAILS WHILE MOVING THE CARRIAGE OR BOGIES. 034-0309

008-0303

Make sure the vibrator will clear the steel in the slab

Before paving operations begin, adjust the pan vibrator up or down so that the bottom of the pan is about 1⁄2 inch (13 mm) below the bottom surface of the drum(s). Check to make sure the vibrator pan or the vibrator fin will clear the steel in the slab. After paving operations have begun, check the vibrator periodically to make sure the vibrator is floating on the surface of the concrete (the rubber pan mounts should be slightly flexed as the carriage moves across the slab). Adjust the vibrator up or down as needed.

Section 15—Starting a pour Notice: Read and understand the appropriate “Operation and finishing procedure” section, below, before starting pouring operations. W

!

WARNING!

!

SEVERE INJURY CAN OCCUR TO PERSONS ON OR AROUND THE MACHINE IF THEY ARE CAUGHT IN ANY MOVING PARTS WHEN THE ENGINE IS STARTED. MAKE CERTAINALL PERSONNEL ARE CLEAR OF THE MACHINE BEFORE ANY ENGINE IS STARTED.

If a wood or metal header will be used at the start of the pour, make sure it is secure and set 1⁄2 inch (13 mm) lower than the bottom of the augers and drum(s) so they will clear the header and finish the concrete from the start of the slab. Start the engine and place the travel direction control valve in the “forward” or “reverse” position and slowly rotate the bogie variable travel speed control valve clockwise to position the machine—with the drums, augers, and vibrators set to grade—so that all carriage parts are behind the header. If the pour will be started at the end of an existing slab, start the engine and place the travel direction control valve in the “forward” or “reverse” position and slowly rotate the bogie variable travel speed control valve clockwise to position the machine—with the drums, augers, and vibrators set to grade—several feet or meters in front of the existing slab. Fill the area between the slab forms and about 10 feet (3 M) in front of the header or existing slab with concrete. The concrete should be about 3 to 4 inches (7.7 to 10 cm) deeper than the slab forms (depending upon concrete slump). Use portable vibrators as necessary to consolidate the first 5 feet (1.5 M) of concrete. If a header is being used, start the engine and place the carriage travel valve in the “on” position to start drum and auger rotation. Move the machine forward until the optional vibrator is over the new concrete and lower it to the correct depth. If the pour is being started at the end of an existing slab, back the machine up until the rear of the drum(s) is just in front of the existing slab and lower the optional vibrator the correct depth into the concrete.

4-17

C-650-F/S 034-0060

undercarriage turntable turned one hole off center (see the “Undercarriage rotation” drawing, above for the correct orientation). Cycle the carriage several times across the concrete to determine the effect of the undercarriage angle, then increase the angle if necessary. Generally, the undercarriage should be rotated more when the concrete slump is higher. As soon as the drums are finishing the concrete correctly, take note of the slump and how far the undercarriage is rotated to ease setup time the next time the same concrete mix design is used. Carriage movement: To finish concrete correctly, the single-drum or Vib-O-Pac 100 undercarriage must move across the concrete twice before the machine moves forward. The first time the carriage moves across the concrete is called the “consolidation pass.” The second time the carriage moves across the concrete is called the “finish pass.”

Start vibrator operation and start moving the carriage across the slab. Move the machine forward at the correct intervals (see the appropriate “Operation and finishing procedure” section, below) until the float pan(s) can be placed on the surface of the finished concrete.

008-0396

Console

Section 16—Machine operation and finishing procedures SINGLE-DRUM OR VIB-O-PAC 100 OPERATION AND FINISHING PROCEDURES During operation of the C-650-F/S with a single-drum or Vib-O-Pac 100 undercarriage, the auger(s), finishing drum and float pan cycle back and forth along the frame. The auger(s) move excess concrete forward andthe cutdrum. it to approximate grade, surface for The finishing drumpreparing compactsthe and finishes the surface of the concrete. The float pan fills in small voids and levels an occasional small ribbon of concrete rolling around the rear of the drum.

Carriage direction

Drum

008-0396

Consolidation Pass

Consolidation Pass: On the first pass, the drum moves away from the operator, rolling over the concrete to spread and compress it. The bottom of the drum spins in the direction of carriage movement. 008-0397

Console

034-0199

Rotate undercarriage so augers point away from the direction of the finish pass

Carriage direction

Drum 008-0397

Direction of finish pass

Finish Pass

Console

Finish Pass: On the second pass, the drum moves back toward the operator, striking the concrete to exact grade, finishing the slab, and carrying excess concrete to the edge. The bottom of the drum spins in the opposite direction of carriage movement.

034-0199

Undercarriage rotation

Undercarriage rotation: Rotate the undercarriage so that the auger(s) point away from the direction of the finish pass. If the C-650-F/S is being used with an untested concrete mix design, start the pour with the

DOUBLE-DRUM OPERATION AND FINISHING PROCEDURES The C-650-F/S double-drum undercarriage is equipped with two drums, two augers, and one or more float pans. The double-drum undercarriage

4-18

C-650-F/S compacts and finishes the concrete in one pass across the slab before the machine moves forward. As the carriage moves across the slab, the augers move excess concrete forward and cut it to approximate grade, preparing the surface for the drums. The bottoms of both drums spin in toward the center of the undercarriage. The first drum spreads and compresses the concrete. The second drum strikes the concrete to exact grade and finishes the slab. The float pan(s) fill in small voids and level an occasional small ribbon of concrete rolling around the rear of the drum. At the end of each pass across the slab, the machine moves forward and the undercarriage automatically rotates to the correct angle. The carriage then begins moving across the frame in the opposite direction. Because both drums spin up toward the center of the undercarriage, the first drum continues to compact the concrete and the following drum continues to finish the concrete.

moves across the slab, the augers move excess concrete forward and cut it to approximate grade, preparing the surface for the drum. The drum vibration spreads and compresses the concrete. If the carriage is moving to the right side of the machine frame (as seen from the front of the machine), the drum rotates counterclockwise. If the carriage is moving to the left side of the machine frame (as seen from the front of the machine), the drum rotates clockwise. The drum strikes the concrete to exact grade and finishes the slab. The float pan(s) fill in small voids and level an occasional small ribbon of concrete rolling around the rear of the drum. 008-0398

Console

Carriage direction

Drum

034-0134

DRUMS

Console

Carriage direction

Drum 008-0398

Vib-O-Pac 200 drum rotation 034-0134

Double-drum rotation

Double-drum rotation: For most applications the undercarriage hoses should be connected to the carriage so the bottoms of the drums spin in toward the center of the undercarriage. A roll of excess concrete forms between the drums, and fills voids in the surface of the concrete. In certain applications the drums may be reversed to turn out on the bottom. Excess concrete carried on the outside of the drums fills voids in the surface of the concrete and is also carried to the edges of the slab during the carriage cycle. VIB-O-PAC 200 OPERATION AND FINISHING PROCEDURES The C-650-F/S Vib-O-Pac 200 undercarriage is equipped with one vibrating drum with a maximum speed of 3850 vpm (vibrations per minute), two augers, and one or more float pans. To finish concrete correctly, the Vib-O-Pac 200 undercarriage moves across the concrete only once before the machine moves forward. As the carriage

Vib-O-Pac 200 drum rotation:At the end of each pass across the slab, the machine moves forward and the undercarriage automatically rotates to the correct angle. The spinning drum automatically reverses so that if the carriage is moving to the right side of the machine frame (as seen from the front of the machine), the drum rotates counterclockwise; if the carriage is moving to the left side of the machine frame (as seen from the front of the machine), the drum rotates clockwise. When the undercarriage has rotated and the drum spin has reversed, the carriage begins moving across the frame in the opposite direction. If the drum does not spin in the correct direction, follow the directions in Chapter III, Section 16—Check drum rotation. SLOPE POUR OPERATION AND FINISHING PROCEDURES During operation of the C-650-F/S on a slope pour, the auger(s), finishing drum and float pan cycle up and down the slope along the frame. The auger(s) moves excess concrete forward and cuts it to approximate grade, preparing the surface for the drum. The finishing drum compacts and finishes the surface of the concrete. The float pan fills in small voids and

4-19

C-650-F/S levels an occasional small ribbon of concrete rolling around the rear of the drum.

the top edge. The bottom of the drum continues to spin towards the top of the slope.

NOTE: If the machine is equipped with double drums and will be used to finish a slope, raise the adjustable drum as high as possible (only one drum is needed to finish a slope).

Notice: If drum rotation is reversed, concrete will be pushed down the slope, and excess concrete will collect at the bottom. 008-0401

To finish concrete correctly on a slope pour, the singledrum undercarriage must move across the concrete twice before the machine moves forward. During the first pass, the carriage moves down the concrete for the “consolidation pass.” During second pass the

Top of Slope

carriage moves back up the slope for the “finish pass.” 008-0395

Rotate undercarriage so augers point away from the direction of the fini sh pass

Console

C

ia g arr

e

Direction of finish pass

n ctio Drum dire

Console

Bottom of Slope 008-0401

Undercarriage rotation

Undercarriage rotation: Generally the drum and auger(s) should be perpendicular to the frame of the machine during a slope pour. However, if the roll of concrete forming under the drum during the finish pass cannot be controlled by slowing the advance of the

008-0395

Consolidation Pass

Consolidat the first the drumto moves downion thePass: slope,On rolling overpass, the concrete spread and compress it. The bottom of the drum spins towards the top of the slope.

machine or lowering the front of the machine, rotate the undercarriage so that the auger(s) point slightly down the slope. Generally, the undercarriage should be rotated more when the concrete slump is higher.

008-0394

If the C-650-F/S is being used with an untested concrete mix design on a slope pour, start the pour with the drum perpendicular to the machine frame. Cycle the carriage several times up and down the slope to determine the effect of the drum angle, then increase the angle of undercarriage rotation by one hole if necessary. Take note of the slump and how far the undercarriage is rotated as soon as the drums are finishing the concrete correctly to ease setup time the next time the same concrete mix design is used.

Console

Ca

g rria

tio irec ed

n

m Dru 008-0394

Finish Pass

Finish Pass: On the second pass, the drum moves back up the slope, striking the concrete to exact grade, finishing the slab, and carrying excess concrete up to

4-20

C-650-F/S Section 17—Finish troubleshooting W

!

WARNING!

!

TO PREVENT SERIOUS INJURY, KEEP HANDS AND FEET CLEAR OF CARRIAGE RAIL, MACHINE RUNNING RAIL, AND ALL MOVING PARTS WHILE THE MACHINE AND CARRIAGE ARE IN OPERATION.

voids). Ideally the concrete roll should extend back no more than 3⁄4 of the length of the drum(s). The roll should taper to nothing at the end of the drum(s). The float pan will finish small voids and an occasional small ribbon of concrete rolling around the rear of the drum(s). Finish troubleshooting: 009-0007A

Drum Speed and Carriage Travel: Drum speed is controlled by the carriage engine rpm. The carriage engine always be operated fullpossible throttle (about (3000 rpm) soshould the drum is spinning as fastatas 330 rpm). Carriage travel speed should be set higher for high slump concrete and lower for low slump concrete. When using a C-650-F/S with a new mix design, cycle the carriage several times across the concrete to determine the effect of the carriage speed, then increase or decrease carriage speed if necessary. To ease setup time the next time the same concrete mix design is used, take note of the concrete mix and the carriage and vibrator speed as soon as the drum is finishing the concrete correctly. Machine advancement: During the pour, move the machine forward every time a new consolidation pass begins. When the machine has moved from 6 inches to 12 inches (15 to 30 cm), stop machine travel until the next consolidation pass begins.

Excessive concrete roll

If too much concrete rolls around the rear of the drum(s) during the pour, it may be caused by one or all of the following: 1. The machine is being advanced too far per cycle. Use shorter machine advance steps. 2. The augers are too high. If the undercarriage is equipped with standard augers, the front of the machine may be too high. When the front is too high, the auger(s) leave too much concrete for the drum(s) to finish. Lower the front of the machine 1⁄8 inch with both front grade jacks.

Note: If the machine is being used with a single drum or is pouring a slope, the machine must move forward only when the carriage reaches one side of the slab. 008-0306

NOTE: One full turn of the grade jacks equals 1⁄8 inch (33 mm). When adjusting the grade jacks up or down, rotate the jack handles one turn, then finish several feet (at least 1.5 M) of slab to determine the effect of the adjustment before rotating the jack handles again. W

! Concrete roll

Exactly how farthat to move machine governed by the roll of concrete formsa along the is front of the drum during the finish pass. To finish concrete best, set up and operate the machine so that the drum(s) carry only a small roll of concrete during the finish pass: 3 inches (7.5 cm) or less (just enough to fill surface

WARNING!

!

TO PREVENT SERIOUS INJURY, KEEP HANDS AND FEET CLEAR OF CARRIAGE AND AUGERS WHILE THE MACHINE IS IN OPERATION. If the machine is equipped with adjustable auger(s), the auger(s) may be too high. Turn the adjusting turnbuckle or jack no more than one complete revolution to lower the auger(s). Allow the carriage

4-21

C-650-F/S to cycle back and forth several times to see if the adjustment reduces the size of the concrete roll. Readjust the auger(s) if necessary.

Section 18—Estimating the rate of pour and concrete usage Use the formula for U.S. units below to calculate the amount of concrete that will be needed for a particular pour when the slab depth is in inches. Use the formula for metric units below to calculate the amount of concrete that will be needed for a particular pour when the slab depth is in centimeters.

3. The concrete is too high in front of the machine. The auger(s) should form a row of concrete no higher than 1⁄2 the height of the augers across the entire width of the slab. If the concrete gets too high, rake it forward. Carefully place concrete in front of the machine to prevent excessive concrete at the auger(s).

U.S. UNITS FORMULA:

NOTE: Make sure the auger(s) and drum(s) always have some concrete in front of them. If the concrete goes below grade in front of the augers and drum(s), there will be a dip in the finished slab. 034-0194

Paving Form

Right:

MORTAR ROLL

DRUM

MORTAR ROLL

DRUM

FORM

EDGE OF SLAB

EDGE OF SLAB

Wrong:

Wrong:

FORM

MORTAR ROLL

DRUM

MORTAR ROLL

DRUM

FORM

EDGE OF SLAB

FORM

EDGE OF SLAB

034-0194

Concrete placement at slab edges

Slope Forms

Horizontal Forms Right:

MORTAR ROLL

DRUM

FORM

EDGE OF SLAB

Wrong: DRUM

METRIC UNITS FORMULA:

EDGE OF SLAB

Wrong:

MORTAR ROLL FORM

100 ÷ slab depth (cm) = Area covered (square meters per cubic meter)

MORTAR ROLL

EXAMPLE PROBLEM (in metric units): How many square meters of slab surface can be finished if a slab is 22 centimeters thick and 30 cubic meters of concrete are delivered to the site?

DRUM

FORM

EDGE OF SLAB

To find how much concrete is needed to finish the

Next, divide the total surface area by the surface area covered with one cubic yard (5120 ÷ 43.2 = 118.5 cubic yards will be needed for this pour).

MORTAR ROLL

FORM

DRUM

SOLUTION: To find how many square feet of slab surface can be covered by 45 cubic yards of concrete, first insert 7 1⁄2 inches into the formula above: divide 324 by 7.5. 324 ÷ 7.5 = 43.2, so one cubic yard of concrete will cover 43.2 square feet if the slab is 7.5 inches thick. If 45 cubic yards of concrete are delivered, 1944 square feet will be paved (45 x 43.2). If 45 cubic yards of concrete are delivered every hour, 1944 square feet will be paved every hour.

pour, first figure out the total surface area: multiply the length (160) by the width (32) to find the total surface area (160 x 32 = 5120 square feet).

009-0021

Right:

(square feet per cubic yard)

EXAMPLE PROBLEM (in U.S. units):How many square feet of slab surface can be finished if a slab is 7 1⁄2 inches thick and 45 cubic yards of concrete are delivered to the site? How much concrete is needed to finish the 7.5 inch deep pour if it is 160 feet long by 32 feet wide?

Bridge deck

Right:

324 ÷ slab depth (in.) = Area covered

EDGE OF SLAB

009-0021

Concrete placement at slope slab edges

Carefully place concrete at the proper grade elevation near the forms or rails to avoid filling large areas with mortar (see the “Concrete placement at slab edges” drawings, above).

How much concrete is needed to finish the 22 centimeter deep pour if it is 55 meters long by 8 meters wide? SOLUTION: To find how many square meters of slab surface can be covered by 30 cubic meters of concrete, first insert 22 centimeters into the formula above: divide 100 by 22. 100 ÷ 22 = 4.55, so one cubic meter of concrete will cover 4.55 square meters if the slab is 22 centimeters thick. If 30 cubic meters of

4-22

C-650-F/S concrete are delivered, 136.5 square meters will be paved (30 x 4.55). If 30 cubic yards of concrete are delivered every hour, 136.5 square meters will be paved every hour. To find how much concrete is needed to finish the pour, first figure out the total surface area: multiply the length (55) by the width (8) to find the total surface area (55 x 8= 440 square meters). Next, divide the total surface area by the surface area covered with one cubic meter (440 ÷ 4.55 = 96.7 cubic meters will be needed for this pour).

4-23

C-650-F/S

4-24

C-650-F/S CHAPTER V—MAINTENANCE ............................................................................................. 5-1 Section 01—Content of chapter ..................................................................................................................... 5-1 Section 02—Fuels .......................................................................................................................................... 5-1 Section 03—Lubricants .................................................................................................................................. 5-1 Section 04—4 or 5 hour service ..................................................................................................................... 5-1 Section 05—10 hour or daily ser vice .............................................................................................................. 5-2 Section 06—50 hour or weekly service .......................................................................................................... 5-7 Section 07—100 hour service ...................................................................................................................... 5-11 Section 08—250 hour service ...................................................................................................................... 5-11 Section 09—500 hour or annual ser vice ...................................................................................................... 5-12 Section 10—Adjusting pressures ................................................................................................................. 5-13 Section 11—Setting the carriage shift delay cylinder (machines with double-drum and Vib-O-Pac 200 undercarriages only) ................................................................................................................ 5-20

C-650-F/S

C-650-F/S containers. Wipe away all grease and dirt before removing filler caps.

CHAPTER V—MAINTENANCE

Grease: Use any multipurpose lithium soap grease for all grease fittings. Apply grease as instructed in this chapter to provide proper lubrication and keep contamination out of bearings and gears.

Section 01—Content of chapter This chapter contains C-650 safety, service, and adjustment instructions for the battery, fuel system (including fuel specifications), engine lubrication (including oil specifications), and hydraulic systems (including pressure adjustment). Perform service and adjustments before setting up the machine. Pay Particular Attention to all Safety Statements.

NOTE: Use only high-grade lubricants which have been stored in clean containers. Wipe away all old grease and dirt before removing filler caps or plugs. Wipe grease fittings clean before lubricating.

Notice: This chapter describes some of the most important C-650 engine maintenance procedures and intervals that were available at the time of publication. However, the engine manual that came with the C-650 may describe procedures and intervals not covered in this chapter. If the procedures and intervals in this chapter are different from the procedures and intervals in the engine manual, follow the recommendations in the engine manual. Before operating the C-650, thoroughly read and understand the engine manual that came with the engine.

Section 04—4 or 5 hour service Before working with the C-650, proper maintenance should be performed to prevent breakdowns and to provide the longest possible life of the machine. The following items should be done twice a day or after every 4 hours of operation. W

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WARNING!

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TO PREVENT SEVERE INJURY, BE CERTAIN THAT ALL PARTS HAVE STOPPED MOVING, THE ENGINE IS STOPPED, THE IGNITION KEYS ARE REMOVED FROM THE CONSOLE, AND THE MASTER DISCONNECT SWITCH IS IN THE “OFF” POSITION BEFORE SERVICING THE MACHINE. MAKE CERTAIN THAT EV ERYONE IN THE AREA KNOWS THAT THE EQUIPMENT IS BEING SERVICED.

Section 02—Fuels To keep the fuel system in its most efficient condition, keep fuel free of contamination. Use only distillate diesel fuel oil, not residual oils or blends. Inspect storage regularly for dirt, water, varnish, emulsioncans sludge and clean them if they are or water contaminated. Do not store diesel fuel in storage containers for prolonged periods. For further information, see the engine owner’s manual. Notice: Fuels outside the specifications in the engine manual may result in excessive engine wear and damage.

Section 03—Lubricants Effective use of proper lubricating oils and grease is perhaps the most important step towards low upkeep cost, long machine life, and satisfactory service. Engine oil: Use only lubricants specified in the engine manual. Change engine oil at the intervals and according to the instructions in the engine manual. Hydraulic Oil: GOMACO recommends any anti-wear hydraulic oil with an I.S.O. viscosity rating of 215 at 100° F (37 ° C) such as Arco Duro AW-46. NOTE: The hydraulic oil should be changed if it is contaminated. Store hydraulic oil in clean

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C-650-F/S 034-0217A

008-0136A

034-0213

Grease fitting on standard drum hanger bearing (1 of 2 per drum) 034-0214

Grease Vib-O-Pac drum and vibrating shaft bearings: If the machine is equipped with a Vib-O-Pac drum with grease fittings, remove the plug(s) on the front and rear of the Vib-O-Pac drum(s) to access the fittings. Add grease to the fittings until resistance is felt against the grease gun handle (1 or 2 pumps). Do not over-grease or the seals may be damaged. The

Grease fitting on Vib-O-Pac drum hanger bearing (1 of 2 per drum)

bearings should twice a day (or after every four or five hoursbe of greased continued use).

Grease the drum hanger bearings: Grease the two drum hanger bearings (on standard and Vib-O-Pac drums) until resistance is felt against the grease gun handle (1 or 2 pumps). Do not over-grease or the seals may be damaged. The bearings should be greased after every four or five hours of continued use.

034-0014A

NOTE: If the machine is equipped with double drums, then all four bearings must be greased.

Section 05—10 hour or daily service Perform all 4 hour maintenance services. W

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Grease the auger hanger bearing(s) (adjustable augers only): Grease the auger hanger bearing(s) until

WARNING!

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A DEFECTIVE EMERGENCY STOP (E-STOP)

resistanceDo is not felt over-grease against the grease gun handle (1 or 2 pumps). or the seals may be damaged. The bearings should be greased twice a day or after every four or five hours of continued use.

SYSTEM MAY CAUSE SEVERE INJURY OR DEATH. DO NOT OPERATE ANY MACHINE WITH AN INOPERATIVE EMERGENCY STOP SYSTEM. CHECK THE EMERGENCY STOP SYSTEM EVERY DAY FOR PROPER WORKING OPERATION. ?0470188

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C-650-F/S 016-0058

Check coolant level: When the engine is cold, remove the radiator cap and check the coolant level. Check the coolant every day before starting the engine. The coolant level should be no more than 1 inch (25 mm) below the bottom of the filler neck.

Emergency stop controls

Check each emergency stop button: Check each emergency stop button each day before beginning operation. Pull out all emergency stop buttons. Place the key switch in the “on” position, and make sure the check emergency stop light comes on. Move the emergency stop reset switch to the “reset” position, and make sure the check emergency stop light goes out.

047-0205A

Depress the console emergency stop button and make sure the emergency stop light comes on. Pull the button out and move the emergency stop reset switch to the “reset” position and repeat for every emergency stop button on the machine. If the check emergency stop light does not come on when any of the emergency stop buttons is pushed in, repair the emergency stop system before operating the machine. 034-0013C

Check engine oil levels: Check the oil level in the engine with the dipstick. Do not or operate the engines when the oil level is below the bottom mark. Wait 10 minutes after stopping the engines before checking the oil. If necessary, add oil to the engine to bring the oil level up to the top mark on the dipstick. C

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CAUTION!

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TO PREVENT ENGINE DAMAGE, NEVER OVERFILL THE ENGINE WITH OIL. CHECK THE OIL LEVEL FREQUENTLY DURING THE INITIAL ENGINE BREAK-IN PERIOD.

Grease the carriage wheels: If the carriage wheels are equipped with grease fittings, grease the four carriage wheels until grease is expelled from between the wheel bushing and the wheel axle.

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C-650-F/S 047-0200

inside. Fill the tank with fresh, clean, distillate diesel fuel. NOTE: Use clean oil and fuel and store in approved clean covered containers. Use clean fill funnels. 047-0186A

Check the engine air filter: Remove, check, and clean or replace the air filter according to directions in the engine manual. C

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CAUTION!

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NEVER RUN THE ENGINE WITHOUT A COMPLETE AIR FILTER UNIT INSTALLED.

Drain Caterpillar engine fuel-water separator: Follow directions in the engine manual to drain the fuel-water separator.

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DANGER!

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USE EXTREME CARE WHEN REFUELING THE ENGINE. NEVER REFILL THE TANK WHEN THE ENGINE IS RUNNING ORHOT. NEVER COMPLETELY FILLTHE TANK. ALWAYS LEAVE THE LEVEL 1 INCH (2.5 CM) BELOW THE NECK OF THE TANK TO ALLOW FOR EXPANSION. ALWAYS WIPE UP ANY FUEL SPILLS AND ALLOW THEM TO EVAPORATE BEFORE STARTING THE ENGINE. 016-0053A

Check engine drive belts: Follow the recommendations in the engine manual to check and tighten the engine drive belts.

Fuel tank

Check engine fuel levels: Check the fuel level in the tank by removing the cap and looking at the level

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C-650-F/S 016-0057

008-0168B

Carriage shift linkage Hydraulic oil level and temperature gauge

Grease the carriage shift linkage: Grease the carriage shift linkage until grease is expelled between the shaft and the bushing.

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W

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WARNING!

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TO PREVENT SEVERE INJURY, BE CERTAIN THAT THE ENGINE IS STOPPED AND ALL PARTS HAVE STOPPED BEFORE SERVICING MOVING PARTS. MAKE CERTAIN THAT EV ERYONE IN THE AREA KNOWS THAT THE EQUIPMENT IS BEING SERVICED. 008-0152

Hydraulic oil filler cap

The should be oil half wayisup theadd gauge whenhydraulic the oil isoil cold. If the level low, oil until the level is halfway up the gauge. Use only the proper grade of hydraulic oil. Notice: To prevent damage to hydraulic components, do not operate the machine when the oil level is below the gauge. NOTE: The hydraulic oil should be changed if it is contaminated. Store hydraulic oil in clean containers. Wipe away all grease and dirt before removing filler caps.

Loose single drum chain

Check the drum drive chain tension: If the chain on a single-drum undercarriage is too tight or too loose (more or less than 1⁄4 inch (6 mm) deflection), remove the chain cover and loosen the four 1⁄2 inch (13 mm) nuts on the bottom rear drum bearing and move the drum up or down until the chain deflects 1⁄4 inch (6 mm). Retighten the nuts on the drum bearing securely. If a drum bearing is adjusted as far as possible and the chain still cannot be tensioned correctly, remove a half or full link from the drive chain.

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C-650-F/S Lubricate the drum drive chain with a suitable chain lubricant. Replace the chain cover.

Grease the bogies (C-650-F only): add grease to the fittings on the drive and idler bogies until grease is expelled.

NOTE: If the drum bearing is adjusted up or down after the machine has been set to grade, recheck the drum-to-grade measurements and readjust as necessary.

Check bogie drive chains tension (C-650-F only): Make sure the bogie drive chains in the deflect 1⁄4 inch (6 mm) between the drive motor sprockets and the sprockets on the drive wheels.

008-0258B

034-0054B

Bogie drive chain adjuster Double drum chain idler sprockets

If the any chain is too tight or too loose (more or less than 1⁄4 inch (6 mm) deflection), loosen the four bolts and the locknut on the bogie chain tightener sprocket and turn the adjusting nut to adjust the drive chain until the chain deflects 1⁄4 inch (6 mm). Tighten the locking bolts and nuts securely.

If the chain on a double-drum undercarriage is too tight or too loose (more or less than 1⁄4 inch (6 mm) deflection), remove the chain cover and loosen the 1⁄2 inch (13 mm) bolt on the idler sprocket and move the sprocket in or out until the chain deflects 1⁄4 inch (6 mm). Retighten the idler sprocket bolt and replace the chain guard.

If a chain tightener sprocket is adjusted as far as possible and the chain still cannot be tensioned correctly, remove a half or full link from the drive

If an idler sprocket is adjusted as far as possible and the chain still cannot be tensioned correctly, remove a half or full link from the drive chain.

chain. Lubricate the bogie drive chains with a suitable chain lubricant.

Lubricate the drum drive chains with a suitable chain lubricant. Replace the chain cover.

Clean and inspect the machine: After all 10 hour or daily maintenance has been performed, walk around the machine and check for any hydraulic leaks; loose bolts, nuts, and setscrews; and worn or damaged parts. Make all adjustments needed to correct the machine’s performance during pouring operations.

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WARNING!

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TO PREVENT SEVERE INJURY, ALL GUARDS AND SHIELDS MUST BE IN PLACE AND SECURED BEFORE THE MACHINE IS STARTED OR USED.

After each use, or before storage, clean all concrete from the C-650 as soon as possible. Remove all concrete and oil the surface of the finishing drum(s) with a light weight oil.

034-0053A

Typical bogie grease fitting

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C-650-F/S Check the engine battery: The electrical circuits are 12 volt negative ground systems. There is a 12 volt battery in the console. Gas produced by the battery is highly flammable—keep sparks and flames away from the battery.

Section 06—50 hour or weekly service Perform all 4, and 10 hour maintenance services. 016-0003B

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CAUTION!

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WHEN SERVICING THE ELECTRICAL SYSTEMS OR WELDING ON THE MACHINE, ALWAYS DISCONNECT BOTH CABLES FROM THE BATTERY TO PREVENT DAMAGE TO THE MACHINE'S ELECTRICAL SYSTEMS. Before connecting the battery, make certain all electrical switches and accessories are turned off. Be certain that the terminals and battery posts are thoroughly cleaned and that the battery cable terminals are tight—dirty or loose connections can create high electrical resistance and cause arcing, which will quickly burn and pit terminals and posts and can ignite battery gasses.

Radiator and hydraulic oil cooler

Check the radiator and hydraulic oil cooler: Make sure the fins on the radiator and hydraulic oil cooler are clean. Use low pressure compressed air or water to remove any dust, dirt, or oil.

Notice: Always connect battery cables correctly— reversed polarity will damage the electrical system. When connecting the battery, connect starter cables to the positive (+) post of the battery. Connect ground cables to the negative (-) post of the battery. When disconnecting batteries, always disconnect the negative cable before disconnecting the positive cable. When

016-0088

connecting batteries, connectcable. the negative cable after connecting the positive Keep the battery clean and check the electrolyte level. If the level is low, fill the cells to the bottom of the filler necks with distilled water or any clean water that is fit to drink and does not have a high mineral content. NOTE: If water must be added in freezing weather, run the engine two or three hours to thoroughly mix the water and electrolyte after adding water.

Battery W

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WARNING!

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BATTERIES CONTAIN SULFURIC ACID AND NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE SERIOUS INJURY . DO NOT ALLOW FLAMES OR SPARKS TO COME NEAR BATTERIES. ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES WHEN CHARGING OR WORKING NEAR BATTERIES. IF BATTERY ACID CONTACTS SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF BATTERY ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY.

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WARNING!

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TO PREVENT AN EXPLOSION OF BATTERY GASSES, DO NOT CONNECT A NEGATIVE JUMPER CABLE DIRECTLY TO THE NEGATIVE POST OF A BOOSTER BATTERY OR A DEAD BATTERY. CONNECT THE ENDS OF THE NEGATIVE JUMPER CABLE TO A GOOD GROUND POINT ON THE MACHINE—AWAY FROM THE BATTERY. When using jumper cables, first connect one end of the positive jumper cable to the positive (+) terminal of

C-650-F/S 047-0212

the dead battery and one end to the positive (+) terminal on the booster battery. Next, connect the booster end of the negative jumper cable to the negative (-) terminal on the booster battery. Finally, connect the last end of the negative jumper cable to a good ground—away from the battery—on the machine with the dead battery. W

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WARNING!

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MOVING TRACKS CAN CAUSE SERIOUS INJURY. BE CERTAIN THAT NO ONE IS NEAR THE TRACKS BEFORE MOVING THE MACHINE. KEEP HANDS, FEET AND LOOSE CLOTHING AWAY FROM MOVING PARTS.? 047-0340

Check the gear oil level in the track drive gearboxes: Rotate the gearboxes until the fill/drain plug is on the top. Remove the check plug from the center of the gearbox. Gear oil should flow from the opening. If not, add EP-90 gear oil until it begins to flow from the check plug opening. Note: If hydraulic oil flows from the check plug hole, the shaft seal on the hydraulic drive motor may have failed. Remove the drive motor and replace the seal. 047-412

Track tension grease fitting

Check track tension: If the top of either track chain can be lifted more than 1 inch (2.5 cm), clean off the button head grease fitting behind the chain idler sprocket and use a grease gun to inject grease until the chain deflects less than 1 inch (2.5 cm).

Pump Drive Gearbox Check and Fill Plugs

Check the pump drive gearbox gear oil level: Remove the check plug in the side of the gearbox. Gear oil should flow from the opening.

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C-650-F/S 047-413

008-0009A

Grease fittings on C-650-F grade jack

Pump drive gearbox fill plug

If the level of oil is low, Add EP-90 gear oil through the fill plug opening until it begins to flow from the check plug opening.

Grease the grade jacks: If the jacks are equipped with grease fittings, add two to three pumps of grease to each fitting.

Note: If hydraulic oil flows from the check plug hole when the plug is removed, the shaft seal on one of the pumps may be defective. One or both pumps must be removed to find and replace the defective seal.

034-0009A

Note: Change the oil in the track drive gear boxes and the pump drive gearbox after the first 50 hours of operation. 047-0193A

Grease fittings for self- or power-widening jack wheels (4 per jack)

Grease the Self- or power-widening jack wheels (C-650-F only): Grease the grease fittings in the four wheels on each self- or power-widening jack mount until grease is expelled from between the wheel bearing bushing and the shaft.

Grease fitting on C-650-S grade jack

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C-650-F/S 034-0174A

008-0172A

008-0354A

PTA chain tightener

Check the PTA chain tension:On machines equipped with power transition adjuster(s) (PTA), check for proper chain tension (1⁄4 inch (6 mm) deflection) between the drive motor and the transition grade adjuster sprocket. If the chain is too tight or too loose, remove the chain cover, loosen the locking bolt on the chain tightener sprocket, and adjust the sprocket until the chain deflects 1⁄4 inch (6 mm) between the sprockets. Retighten locking bolt securely. Self- or power-widening jack wheel adjustments (old and new style shown)

Lubricate the PTA drive chain with a suitable chain lubricant and grease the threaded adjusting rods. 008-0172B

Check the self- or power-widening jack wheels: Make sure the self- or power-widening jack wheels have about a 1⁄16 inch (2 mm) gap between the jack rails and the bottom of the wheels. If the wheels are too tight or too loose, loosen the wheel shaft bolt and tighten the 1⁄2 inch (13 mm) adjusting bolt. Tighten the locknut securely. NOTE: Do not overtighten the wheel locking bolt or the wheels will not roll freely on the selfwidening rail.

PTA sprocket grease fittings

Grease the PTA sprocket bearings: Grease the PTA sprocket bearing grease fittings until grease is expelled from the sprockets and their axles. Replace the PTA chain cover. W

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WARNING!

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TO PREVENT SEVERE INJURY, ALL GUARDS AND SHIELDS MUST BE IN PLACE AND SECURED BEFORE THE MACHINE IS STARTED OR USED.

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C-650-F/S 016-0039B

Section 07—100 hour service Perform all 4, 10, and 50 hour maintenance services. 034-0132

PTA turnbuckle grease fittings Grease the PTA turnbuckles:Grease the PTA adjuster screws until grease is expelled from the threads. 008-0634A

Vib-O-Pac load adapter vent

Change Vib-O-Pac load adaptor oil: If the machine is equipped with a Vib-O-Pac, and the Vib-O-Pac is equipped with a load adapter vent, remove the load adaptor and motor assembly from the undercarriage, remove the brass vent on top of the load adaptor, drain out all the oil, and dispose of properly. Replace with about 2 ounces (59 ml) of Arco Duro AW 46 or equivalent and make sure the oil is about 2⁄3 of the way up in the reservoir. Reinstall the brass vent and load adaptor/motor assembly.

Grease the carriage roller axles

Grease the carriage roller axles: If the carriage is equipped with eight roller, add grease the fitting on the top of each set of carriage rollers until grease is expelled from around the axle.

Section 08—250 hour service Perform all 4, 10, 50, 100, and 200 hour maintenance services.

008-0198

Perform scheduled oil sampling (S•O•S) on Caterpillar engines: If the machine is equipped with a Caterpillar 3054 engine, follow the directions in the engine manual to check oil quality.

Grease the undercarriage rollers

Grease the undercarriage rollers: If the undercarriage is equipped with rollers, add grease to the fitting on each of the eight rollers until grease is expelled from around the roller axle.

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Section 09—500 hour or annual service Perform all 4, 10, 50, 100, and 250 hour maintenance services. 047-0222

Engine fuel filter Caterpillar engine fuel transfer pump strainer

Clean the Caterpillar engine fuel transfer pump strainer: If the machine is equipped with a Caterpillar 3054 engine, follow directions in the engine manual to clean the Caterpillar engine fuel transfer pump strainer. 047-0192

Change Caterpillar engine oil, oil filter(s), and fuel filters: If the machine is equipped with a Caterpillar 3054 engine, follow directions in the engine manual to change the engine oil, oil filter(s), and fuel filters. Check the engine cooling system: Follow the directions in the engine manual to test the coolant for proper antifreeze and additive concentrations.

Engine oil filter

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before removing filler caps. Store hydraulic oil in clean containers. 016-0038A

047-428

Rotary stinger vibrator

Service rotary stinger vibrator: If the carriage is equipped with a stinger vibrator, repack the eccentric bearings every 500 hours or yearly. See the appropriate GOMACO vibrator brochure for instructions on Wyco or Minnich vibrator overhaul.

Section 10—Adjusting pressures W

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WARNING!

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ONLY QUALIFIED PERSONNEL SHOULD ADJUST RELIEF VALVES AND HYD RAULIC PRESSURES. HYDRAULIC OIL UNDER HIGH PRESSURE CAN CAUSE SERIOUS INJURY—MAKE SURE ALL HYDRAULIC CONNECTIONS ARE TIGHT TO PREVENT HOT, HIGH PRESSURE OIL FROM PENETRATING AND BURNING SKIN. TO PREVENT INJURY AND MACHINE DAMAGE, DO NOT TURN ON ANY HYDRAULIC SYSTEM WITH DEADHEADED, PLUGGED, OR CAPPED LINES UNTIL YOU HAVE ADJUSTED THE RELIEF VALVES TO A MINIMUM SETTING.

Main hydraulic oil filter

Change the hydraulic oil filter: The hydraulic oil filter is under the bottom side of the main tank. Place a flat pan under the main filter, remove the four bolts, and remove the filter cover with the spring retainer and filter (the hydraulic oil does not have to be drained before filter replacement). Remove the filter element and discard. Check the Oring on the cover and replace if it is worn or damaged. Place a new filter on the base and reinstall the cover and new filter. Notice: The hydraulic oil filter should be replaced after the first 50 hours of operation. Test the hydraulic oil: Have the hydraulic oil tested by a qualified specialist. Treat or replace the hydraulic oil as indicated by the test results. NOTE: The hydraulic oil should be changed if it is contaminated. Wipe away all grease and dirt

NOTE: All tests and adjustments should be performed when hydraulic oil is warm (130 ° F (55° C)). To adjust the hydraulic pressures on the C-650, a 3000 psi (207 bar) pressure gauge and various fittings are needed. To find out exactly what fittings are needed, read the appropriate description below before beginning adjustments. ADJUST TRAVEL/PTA/OPTIONAL CONSOLE VIBRATOR CIRCUIT PRESSURE: To adjust the travel/PTA/optional console vibrator pressure, a 3000 psi (207 bar) pressure gauge connected to a 3⁄8 inch (13 mm) female quick coupler

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is needed. Connect the pressure gauge to the PTA male quick coupler. 016--0090A

Oil temperature gauge Travel E-Stop vented relief

The travel/PTA/optional console vibrator relief is on the output port of the rear stage of the console pump. Loosen the locking nut on the vented relief and turn the relief adjusting screw out (counterclockwise) 3 to 4 complete turns. If the machine is equipped with one or more console vibrators, disconnect the vibrators and loop the vibrator hoses coming from the console. Turn the vibrator variable(s) on the additional vibrators all the way off (completely clockwise). Make sure all controls and gauges are in the “neutral” or “off” position. Start the engine and allow it to idle, and reset the E-Stop system. Make sure the travel control valve is in the “neutral” position. If the console is equipped with a travel/vibrator on/off switch, place it in the “on” position. Place the PTA valve in the “up” position and slowly rotate the bogie variable travel control in the “increase” direction (clockwise) while watching the pressure gauge connected to the PTA quick coupler. If the pressure gauge begins to exceed 2150 psi (148 bar), quickly rotate the bogie variable travel control counterclockwise to the “off” position. Turn the relief adjusting screw on the E-Stop vented relief out (counterclockwise) 3 or 4 more turns. Repeat until the gauge reads less than 2150 psi (148 bar) with the bogie variable travel control turned completely clockwise.

Increase engine rpm to maximum (2150 rpm) and allow the engine to run until the hydraulic oil temperature gauge reads 130 ° F (55° C). When the oil is at 130° F (55° C) check the pressure gauge connected to the “left pressure” quick coupler. If the gauge reads more than 2150 psi (148 bar) when the hydraulic oil temperature gauge reads 130 ° F (55 ° C), turn the relief on the E-Stop vented relief out (counterclockwise) until it reads 2150 psi (148 bar). Tighten the locknut on the E-Stop vented relief securely. If the gauge reads less than 2150 psi (148 bar) when the hydraulic oil temperature gauge reads 130 ° F (55 ° C), turnrelief the relief adjusting until screw ongauge the E-Stop vented in (clockwise) the reads 2150 psi (148 bar). Tighten the locknut on the E-Stop vented relief securely. Place all controls in the “neutral” or “off” position and shut off the engine. Before connecting quick couplers, thoroughly clean them to prevent dirt from entering the hydraulic system. Connect the protective covers together to keep the covers clean when the quick couplers are connected. After disconnecting quick couplers, always place the protective covers over/in them to keep dirt from entering the hydraulic system. Reconnect the PTA quick couplers. Proceed to the next section: Adjust optional console vibrator pressures. ADJUST OPTIONAL CONSOLE VIBRATOR PRESSURES. Follow directions in the heat consolethe hydraulic oil to 130°section F (55 ° above C) andtoset thethe preceding circuit pressures correctly. Follow the directions below to set the relief pressure for one optional console vibrator circuit. If the machine is equipped with more than one optional

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C-650-F/S console vibrator circuit, repeat the procedure below on each additional console vibrator circuit.

console vibrator circuits and proceed to the next section: Adjust the carriage pressure.

098-0180B

Before connecting quick couplers, thoroughly clean them to prevent dirt from entering the hydraulic system. Connect the protective covers together to keep the covers clean when the quick couplers are connected. After disconnecting quick couplers, always place the protective covers over/in them to keep dirt from entering the hydraulic system. ADJUST CARRIAGE PRESSURE: Follow the directions in the sections above to heat the console hydraulic oil to 130° F (55 ° C) and set the preceding circuit pressures correctly. 016-0065

Console vibrator relief

Disconnect the console vibrator quick couplers and connect a 3000 psi (207 bar) pressure gauge to the male quick coupler. Loop the hoses on any additional console vibrator circuits. Loosen the locknut on the vibrator variable relief adjusting screw (on the top of vibrator variable) and turn the adjusting screw out (counterclockwise) 3 or 4 turns. Place all controls in the “neutral” or “off” position. Turn the console vibrator variable(s) completely clockwise to the “0” position. While the console hydraulic oil temperature is still at 130 ° F (55° C), start the engine and let it idle. Reset the E-Stop system. If the console is equipped with a travel/vibrator on/off switch, place it in the “on” position. Slowly rotate the console vibrator variable connected to the pressure gauge while watching the pressure gauge. If the pressure gauge begins to exceed 1850 psi (127 bar), quickly turn the vibrator variable completely counterclockwise to the “0” position. Turn the vibrator variable relief adjusting screw out (counterclockwise) 3 to 4 more complete turns. Repeat until the gauge reads less than 1850 psi (127 bar) with the vibrator variable turned completely counterclockwise.

Carriage E-Stop vented relief

The carriage E-Stop vented relief is on the output port of the front stage of the console pump. Loosen the locking nut on the vented relief and turn the relief adjusting screw out (counterclockwise) 3 to 4 complete turns. Disconnect the two large quick couplers between the console and the hose reel. Place all controls in the “neutral” or “off” position. While the console hydraulic oil temperature is still at 130° F (55° C), start the engine and allow it to idle. Reset the E-Stop system.

Increase the engine speed to maximum. Turn the relief adjusting screw in (clockwise) or out (counterclockwise) until the pressure gauge reads 1850 psi (127 bar). Place all controls in the “neutral” or “off” position and shut off the engine. Tighten the locknut on the vibrator variable relief adjusting screw securely. Remove the pressure gauge and reconnect the console vibrator quick couplers to the correct vibrator. Repeat the procedure above on any additional

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008-0272B

Pressure gauge connected to drum pressure quick coupler

Carriage pressure gauge Slowly move the carriage travel control towards the “on” position while watching the carriage pressure gauge on the front of the console. If the pressure gauge begins to exceed 2350 psi (162 bar), quickly move the carriage travel control to the “off” position. Turn the carriage E-Stop vented relief adjusting screw out (counterclockwise) 3 to 4 more complete turns. Repeat until the gauge reads less than 2350 psi (162 bar) with the carriage travel control placed in the in the “on” position.

Disconnect the 1⁄2 inch (13 mm) quick couplers going to the drum (if the undercarriage is equipped with adjustable augers, make sure they are disconnected also). Connect the pressure gauge with the 1⁄2 inch (13 mm) male quick coupler to the female quick coupler on the drum hose coming from the flow divider. 016-0091

Increase the engine speed to maximum (2150 rpm). Turn the relief adjusting screw in (clockwise) or out (counterclockwise) until the pressure gauge reads 2350 psi (162 bar). Place all controls in the “neutral” or “off” position and shut off the engine. Tighten the locknut on the carriage E-Stop vented relief securely. Reconnect the large quick couplers between the console and the hose reel. Proceed to the next section: Adjust single- or double-drum relief pressure. ADJUST SINGLE- OR DOUBLE-DRUM RELIEF PRESSURE: Follow the directions in the sections above to heat the console hydraulic oil to 130° F (55° C) and set the preceding circuit pressures correctly. A 3000 psi (207 bar) pressure gauge connected to a 1 ⁄2 inch (13 mm) male quick coupler is needed to adjust the drum relief pressure.

Drum circuit relief valve

While the console hydraulic oil is still at 130 ° F (55 ° C), remove the acorn nut from the top of the drum relief. Loosen the locking nut and turn the relief adjusting screw out (counterclockwise) 3 to 4 complete turns. Place all controls in the “neutral” or off position, start the engine, and allow it to idle. Reset the E-Stop system. Slowly move the carriage travel control on the console to the “on” position while watching the gauge connected to the 1⁄2 inch (13 mm) drum pressure quick coupler. If the pressure gauge begins to exceed 2150 psi (148 bar), quickly move the carriage travel control back to the “off” position. Turn the carriage drum relief

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C-650-F/S adjusting screw out (counterclockwise) 3 to 4 more complete turns. Repeat until the gauge reads less than 2150 psi (148 bar).

carriage travel control on the console in the “on” position to start drum rotation. W

Increase the engine speed to maximum (2150 rpm). Turn the relief adjusting screw in (clockwise) or out (counterclockwise) until the pressure gauge reads 2150 psi (148 bar).

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WARNING!

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TO PREVENT SERIOUS INJURY, KEEP CLEAR OF MOVING DRUM(S) AND AUGERS. 016-0092

Place all controls in the “neutral” or “off” position and shut off the engine. Securely tighten the locknut on the drum relief adjusting screw and replace and securely tighten the acorn nut. Remove the pressure gauge and reconnect the quick couplers to the drum(s). Proceed to the next section: Adjust the single- or double-drum counterbalance pressure. Before connecting quick couplers, thoroughly clean them to prevent dirt from entering the hydraulic system. Connect the protective covers together to keep the covers clean when the quick couplers are connected. After disconnecting quick couplers, always place the protective covers over/in them to keep dirt from entering the hydraulic system. ADJUST THE SINGLE- OR DOUBLE-DRUM COUNTERBALANCE PRESSURE: Follow the directions in the sections above to heat the console hydraulic oil to 130° F (55° C) and set the preceding circuit pressures correctly. 008-0057

Drum counterbalance valve and pressure gauge

While the drum(s) turn freely, check the pressure gauge plumbed into the counterbalance valve manifold. If the gauge reads 500 psi (35 bar) as the drum(s) turn freely, the drum counterbalance pressure is set correctly. Place all controls in the “off” or “neutral” position and shut off the engine. Replace the locknutProceed on the counterbalance reliefAdjust and tighten securely. to the next section: the carriage drive pressure. If the gauge does not read 500 psi (35 bar) as the drum(s) turn freely, loosen the locknut on the relief valve and turn the adjusting screw out (counterclockwise) to increase the pressure or in (clockwise) to decrease the pressure. NOTE: The counterbalance relief adjustment is opposite of a standard relief setting. Turning the adjusting screw “in” (clockwise) decreases the pressure and “out” (counterclockwise) increases the pressure.

Drum quick couplers connected

Make sure both 1⁄2 inch (13 mm) female quick couplers are connected to the undercarriage drum motor(s) (if the undercarriage is equipped with adjustable augers, make sure they are also connected normally). Make sure the finishing drums are not in contact with anything and will be able to turn freely. Place all controls are in the “off” or “neutral” position. While the hydraulic oil is still at 130 ° F (55° C), start the engine and increase engine speed to maximum rpm (2150 rpm). Reset the E-Stop system. Place the

When the counterbalance pressure gauge reads 500 psi (35 bar), place all controls in the “off” or “neutral” position and shut off the engine. Replace the locknut on the counterbalance relief and tighten securely. Proceed to the next section: Adjust the carriage . drive pressure ADJUST THE CARRIAGE DRIVE PRESSURE: Follow the directions in the sections above to heat the console hydraulic oil to 130° F (55 ° C) and set the preceding circuit pressures correctly.

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C-650-F/S Reverse the directions in Chapter III, Section 18— Install the carriage drive chains to remove the carriage chains from the carriage and machine frame. Disconnect the 1⁄2 inch (13 mm) hose coming from the “CF” port in the carriage travel variable valve on the carriage. Install a T-fitting in the “CF” port with a 3000 psi (207 bar) pressure on one outlet and a cap on the other outlet. Remove the acorn nut covering the carriage variable travel relief adjusting screw (on top of the carriage variable travel valve) and turn the adjusting screw out (counterclockwise) 3 or 4 turns. 016-0067

ADJUST THE CARRIAGE DRIVE COUNTERBALANCE PRESSURE: The carriage drive counterbalance valves keep the carriage from moving faster than it is designed to move. To keep the carriage from moving when paving a flat slab, set the counterbalance valves to 500 psi (35 bar) To keep the carriage from moving when paving a slope, set the counterbalance valves to at least 700 psi (48 bar). If the carriage continues to move down the slope when the carriage variable control is in the “0” position, or moves too quickly down the slope (because of the angle of slope or the weight of the carriage), set the counterbalance valves higher than 700 psi (48 bar). Follow the directions in the sections above to heat the console hydraulic oil to 130° F (55 ° C) and set the preceding circuit pressures correctly. Remove the cap from the T-fitting (installed in the Adjust the carriage drive pressure section above) and connect the 1⁄2 inch hose from the cushion cylinder (normally connected to the “CF” port on the carriage variable travel valve) to the open port in the T-fitting. Disconnect both quick couplers going to the drum drive motors and optional adjustable augers.

Carriage variable travel and relief valve

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Place all controls in the “neutral” or “off” position. While the console hydraulic oil temperature is still at 130° F (55 ° C), start the engine and allow it to idle. Reset the E-Stop system. Place the carriage travel Slowly control on carriage the console in the “on” position. rotate the travel variable on the carriage clockwise while watching the pressure gauge attached to the T-fitting.

If the pressure gauge begins to exceed 2150 psi (148 bar), quickly move the carriage variable travel control counterclockwise to the “0” position. Turn the carriage variable travel relief adjusting screw out (counterclockwise) 3 to 4 more complete turns. Repeat until the gauge reads less than 2150 psi (148 bar) with the carriage variable travel control rotated completely clockwise. Increase the engine speed to maximum (2150 rpm). Turn the relief adjusting screw in (clockwise) or out (counterclockwise) until the pressure gauge reads 2150 psi (148 bar).

Carriage drive counterbalance valves

While the console hydraulic oil is still at 130 ° F (55 ° C), rotate the carriage variable travel valve on the carriage fully clockwise. Place all other controls in the “neutral” or “off” position. W

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Place all controls in the “neutral” or “off” position and shut off the engine. Replace the acornscrew nut onand the carriage variable travel relief adjusting tighten securely. Proceed to the next section: Adjust the carriage drive counterbalance pressure.

WARNING!

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TO PREVENT SEVERE INJURY, DO NOT CONTACT ROTATING SPROCKETS. Start the engine and pull the throttle out all the way. Reset the E-Stop system. Place the carriage travel valve on the console in the “on” position to start rotating the carriage drive sprockets.

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C-650-F/S As the carriage drive sprockets turn, check the pressure gauge teed into the “CF” port on the carriage variable travel valve. The gauge should read 500 psi (35 bar) (700 psi (48 bar) or more for slope paving) as the carriage sprockets turn. Push or pull the carriage shift rod on the back of the carriage to change the rotation of the carriage drive motors. The gauge should read 500 psi (35 bar) (700 psi (48 bar) or more for slope paving) as the carriage sprockets turn in the opposite direction. If the gauge reads 500 psi (35 bar) (700 psi (48 bar) or more for slope paving) as the carriage drive sprockets turn in both directions, the counterbalance reliefs are set correctly. Place all controls in the “off” or “neutral” position and shut off the engine. Remove the T-fitting and gauge and reconnect the 1⁄2 inch hose to the “CF” port on the carriage variable travel valve. Proceed to the next section: Adjust single- or double-drum circuit pressure If the carriage pressure gauge does not read 500 psi (35 bar) (700 psi (48 bar) or more for slope paving) as the carriage drive sprockets turn in one direction, one of the counterbalance valves needs to be adjusted (each counterbalance valve controls the counterbalance pressure against the carriage drive motors when the carriage drive sprockets turn in only one direction).

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Disconnect the 1⁄2 inch (13 mm) quick couplers going to the drum and optional adjustable auger drive motors. Disconnect both 3⁄8 inch (10 mm) quick

one relief out (counterclockwise) to increase the pressure or in (clockwise) to decrease the pressure. NOTE: Counterbalance valves are adjusted in the opposite direction from standard relief valves. Turn the screw in (clockwise) to decrease counterbalance pressure. Turn the screw out (counterclockwise) to increase counterbalance pressure.

When both counterbalance pressures are correct, place all controls in the “off” or “neutral” position and shut off the engine. Replace the locknuts on the

A 3000 psi (207 bar) pressure gauge connected to a 3 ⁄8 inch (10 mm) female quick coupler is needed to set vibrator relief pressure(s). If the carriage is equipped with more than one vibrator circuit, repeat the procedure below to set the pressures on all circuits.

Pressure gauge connected to vibrator pressure quick coupler

To adjust the counterbalance pressure, loosen the locknuts on both relief valves and turn the screw on

If one of the counterbalance valves has no effect on the pressure as the carriage drive sprockets turn in one direction, adjust the other counterbalance valve. Adjust both relief valves until the carriage pressure gauge reads 500 psi (35 bar) as the carriage drive sprockets turn in both directions.

ADJUST OPTIONAL CARRIAGE VIBRATOR RELIEF(S): Follow the directions in the sections above to heat the console hydraulic oil to 130° F (55 ° C) and set the preceding circuit pressures correctly.

couplers going from the carriage to the3 vibrator. Connect the pressure gauge with the ⁄8 inch (10 mm) female quick coupler to the male quick coupler on the vibrator hose. Remove the acorn nut from the top of the vibrator variable control on the carriage. Turn the relief adjusting screw out (counterclockwise) 3 to 4 complete turns. Place all controls in the “neutral” or “off” position. While the hydraulic oil is still at 130 ° F (55° C), start the engine let it idle. Reset the E-Stop system. Place the carriage travel control on the carriage in the “on” position. If the carriage and/or console is equipped with a remote vibrator on/off switch, place the switch(es) in the “on” position. Slowly rotate the vibrator variable control in the “increase” direction while watching the pressure gauge connected to the vibrator quick-coupler.

reliefs and tighten securely. Remove the T-fitting and gauge and reconnect the 1⁄2 inch hose to the “CF” port on the carriage variable travel valve. Proceed to the next section: Adjust optional carriage vibrator relief(s).

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C-650-F/S 008-0418

Section 11—Setting the carriage shift delay cylinder (machines with double-drum and Vib-O-Pac 200 undercarriages only) If the carriage is equipped with an adjustable carriage shift delay cylinder, the cylinder does not have to be adjusted unless the carriage stops for too long at the sides of the slab, or begins moving away from the sides of the slab before the undercarriage rotates to the correct angle of attack. 008-0486A

Turning the relief adjusting Allen screw

If the pressure gauge begins to exceed 2150 psi (148 bar), quickly rotate the vibrator variable control counterclockwise to the “0” position. Turn the relief adjusting screw on the top of the vibrator variable control out (counterclockwise) 3 to 4 more complete turns. Repeat the procedure until the gauge reads less than 2150 psi (148 bar). Increase the engine speed to maximum (2150 rpm). Turn the relief adjusting screw in (clockwise) or out (counterclockwise) until the pressure gauge reads 2150 psi (148 bar).

Adjusting a typical carriage shift delay cylinder

When the relief is adjusted correctly, place all controls in the “neutral” or “off” position and shut off the carriage engine. Replace the acorn nut over the vibrator variable pressure adjusting screw and tighten securely. Remove the pressure gauge and reconnect the quick couplers to the vibrator. If the carriage is equipped with more than one vibrator circuit, repeat the procedure above to set the pressures on the additional vibrator circuit(s). Reconnect the drum and optional adjustable auger quick couplers and reinstall the carriage chains according to the directions in Chapter III, Section 18—Install the carriage chains.

To adjust the carriage shift delay cylinder, shut off the engine and turn both valves in (clockwise) all the way, then out (counterclockwise) one to two complete turns.

Before connecting quick couplers, thoroughly clean them to prevent dirt from entering the hydraulic system. Connect the protective covers together to keep the covers clean when the quick couplers are connected. After disconnecting quick couplers, always place the protective covers over/in them to keep dirt from entering the hydraulic system.

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