PF161 Ops and Maint_13858741

OPERATION AND MAINTENANCE MANUAL Ingersoll-Rand Blaw Knox PF-161 Paver/Finisher

CPN 13858741

March 6, 2006

Read and understand this manual before operating or servicing this equipment.

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

TABLE OF CONTENTS

TITLE

SECTION

INTRODUCTION

PROCEDURE WHEN RECEIVING THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 IDENTIFICATION IDENTIFICATION DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MACHINE IDENTIFICATION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL GENERAL INFORMATION. INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MACHINE MACHINE DESCRIPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ELECTRICAL ELECTRICAL SYSTEM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 HYDRAULIC HYDRAULIC SYSTEM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FUEL SYSTEM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TRACTION TRACTION DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TRACTION TRACTION LOCK SYSTEM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PIVOT STEERING STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FRONT SUSPENS SUSPENSION ION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OPERATOR’S OPERATOR’S UMBRELLA UMBRELLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TRUCK HITCH HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 POWER FLOW FLOW GATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DUAL FEED FEED SYSTEMS SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CONVEYORS CONVEYORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 AUGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 AUTOMATIC FEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MAT KONTROL® KONTROL® II WITH WITH PADDLE SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MAT KONTROL® II WITH ULTRA 3S® SENSORS SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SMOKE-EATER® SMOKE-EATER® VENTILATION VENTILATION CONTROL SYSTEM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 WASHDOWN WASHDOWN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CONTROLS CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SCREED CHOICES/SCREED OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SCREED HEATERS HEATERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DIESEL ONLY ONLY HEATERS. HEATERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DIESEL HEATERS HEATERS WITH AUTOMATIC AUTOMATIC TEMPERATURE TEMPERATURE AND IGNITION IGNITION CONTROL (ATIC) (ATIC) . . . . 13 PROPANE (LPG) HEATERS WITH ATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 WEDGE-LOCK® WEDGE-LOCK® SCREED. SCREED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 WEDGE-LOCK® SCREED EXTENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.5/5B HYDRAULIC HYDRAULIC SCREED SCREED EXTENSIONS EXTENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 POWER SLOPE SLOPE OPTION FOR 2.5/5B 2.5/5B HYDRAULIC HYDRAULIC EXTENSIONS. EXTENSIONS. . . . . . . . . . . . . . . . . . . . . . . . 14 BERM ATTACHMENT ATTACHMENT OPTION OPTION FOR 2.5/5B 2.5/5B HYDRAULIC HYDRAULIC EXTENSIONS EXTENSIONS . . . . . . . . . . . . . . . . . . . 15 OMNISCREED® OMNISCREED® IA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 GENERAL GENERAL EQUIPMENT EQUIPMENT OPTIONS OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Front Wheel Wheel Power Assist Assist Option. Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Material Material Indicator Indicator Kit Option Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Blaw-Kontroll® Blaw-Kontroll® II II Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 UltraEye® V Grade Sensor Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Automatic Level Control ( Also Known as a Joint Matcher) Option . . . . . . . . . . . . . . . . . . . . . . . 17 Floating Floating Beam Referenc Reference e Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Mat Reference Reference Option Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Additional Operator’s Umbr ella Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 IDENTIFICATION IDENTIFICATION OF OF MAJOR COMPONEN COMPONENTS TS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

PF-161 Paver/Finisher

1

TABLE OF CONTENTS

TITLE

SECTION

SAFETY

BE AWARE OF SAFETY SAFETY INFORMATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 UNDERSTAND UNDERSTAND SIGNAL SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 OVERVIEW. OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 WARNINGS WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 GENERAL GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 SELECTION SELECTION AND QUALIFICA QUALIFICATION TION OF PERSONNEL PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 ORGANIZATIONAL ORGANIZATIONAL MEASURES MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 MANDATORY MANDATORY SAFETY SAFETY MEASURES MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 LOADING AND AND UNLOADING UNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Loading Loading Dock with with Ramp (Preferre (Preferred d Method) Method) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Alternate Ramp Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 PRE-START PRE-START INSPECTION. INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 SAFETY INSTRUCTI INSTRUCTIONS ONS GOVERNING GOVERNING OPERATION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Operating Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Stopping Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Maintenance. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 HAZARDOUS HAZARDOUS SUBSTANCE SUBSTANCE PRECAUTIO PRECAUTION N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 WARNING OF OF SPECIAL SPECIAL DANGERS DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

ASSEMBLY

GENERAL GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 GENERAL GENERAL ASSEMBLY. ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Before you you Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Selecting Selecting a Site for for Assembly. Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Unloading Unloading the Machine Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Installation Installation of the Steering Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Installation Installation of the Edger-Plate Edger-Plate Assemblies. Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Installation Installation of the Automatic Automatic Feed Feed Control Sensors Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Installation Installation of the Paddle Sensors Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Installation Installation of Ultra Ultra 3s Ultra Ultra Sonic Sensor Sensors s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Muffler Installa Installation tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 OPTIONAL INSTALL INSTALLATION ATION GUIDELINES. GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Installation Installation of the Cut-off Plate Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Installation Installation of of Additional Additional Augers Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Installation of 1-foot Bolt-on Screed Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Installation Installation of the 18-inch 18-inch Tapered-Jo Tapered-Joint int Extension Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Installation Installation of the 8-foot 8-foot Wedge-lock Wedge-lock Screed Screed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Installation of Ultrasonic 4 Sonic Averaging System/Sonic Joint Matcher . . . . . . . . . . . . . . . . . 2-28 Installation Installation of the Ags (7.5) Controll Controllers ers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

OPERATING CONTROLS AND INSTRUMENTS

2

DIRECTION-SPEE DIRECTION-SPEED D CONTROL LEVERS LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Steering Steering Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 MAIN CONTROL CONTROL PANEL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Engine Tachome Tachometer/Hour ter/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Maintenance Maintenance Indicato Indicatorr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Wait to Start Start Indicator Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 PF-161 Paver/Finisher

TABLE OF CONTENTS

TITLE

SECTION

Water in Fuel Fuel Indicator Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Stop Engine Engine Indicator Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Check Engine Engine Indicat Indicator or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Brake Engage Engaged d Indicator Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Empty Tunnel Tunnel Indicator. Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Hydraulic Hydraulic Filter Filter Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Water Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Battery Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Oil Temperature Temperature Gauge Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Front Wheel Assist Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Starter Button Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Engine Kill Kill Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Transmission Transmission Shift Shift Switch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Motor Shift Shift Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 RH Flowgate Flowgate Control Control Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 LH Flowgate Flowgate Control Control Switch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Screed Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Auger Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Hopper Hopper Control Switch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Horn Button Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 RH and LH Conveyor Conveyor Switches Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Parking Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Screed Vibrator Vibrator Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Governor Governor Switch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Throttle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Positive Positive Traction Traction Switch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Pivot Steer Steer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Truck Hitch Hitch In/Out In/Out Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Ventilation Ventilation Control Control Switch. Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Brake Release Release Hand Hand Valve Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Brake Release Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Material Material Indicator Indicator (Option) (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Flow Gate Position Position Indicato Indicators rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Rear Control Control Stations Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Jog Toggle Toggle Switch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Up/Down Up/Down Indicators Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3-Position 3-Position Function Function Toggle Toggle Switch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Slope/Grade Slope/Grade Controlle Controllerr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Mode Switch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Warning Indicator Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Warning Indicator Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Up/Down Up/Down Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Selector Selector Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Screed Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 LH Control Control Panel Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Extension Extension Slope Slope Toggle Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 LH and RH Flow Flow Gate Control Control Toggle Toggle Switches Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Auger Override Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Auger Extension Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Extension Extension Heater Heater Igniter Igniter Switch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Extension Extension Fuel Fuel Pump Switch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Main Fuel Pump Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Main Igniter Igniter Power Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 PF-161 Paver/Finisher

3

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TITLE

SECTION

Auger Speed Control Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Screed Extensio Extension n In/Out Toggle Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 RH Control Control Panel Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Extension Extension Fuel Fuel Pump Switch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Extension Extension Heater Heater Igniter Igniter Switch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Auger Override Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Auger Extension Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Fuel Pump Pump Switch. Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Extension Extension Slope Slope Toggle Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Screed Extensio Extension n In/Out Toggle Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Auger Speed Control Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Main Igniter Igniter Power Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Main Fuel Pump Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

OPERATING INSTRUCTIONS

GENERAL GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Pre-Start Pre-Start Checks and and Verifications. Verifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Starting the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Suggestions Suggestions to Make Make Cleanup Cleanup Easier Easier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Positioning Positioning the Machine Machine and and its Controls Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Initial Screed Screed Elevati Elevation on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Initial Screed Screed Angle-o Angle-of-Attac f-Attack k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Lighting Lighting the Screed Screed Heater. Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Positioning Positioning the Material Material Truck and and Starting to Pave. Pave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 OPERATING OPERATING THE MACHINE MACHINE - GENERAL GUIDELINE GUIDELINES S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 MOVING THE THE MACHINE MACHINE - UNDER PROPULSI PROPULSION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 MOVING THE THE MACHINE MACHINE BETWEEN BETWEEN WORKSITES WORKSITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Securing Securing the Machine Machine to the Transporter Transporter (Tiedown (Tiedown)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 TOWING THE THE MACHINE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

MAINTENANCE INSTRUCTIONS

GENERAL GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 CLEAN UP UP AND WASHDOWN WASHDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Lubricants Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 LUBRICATION LUBRICATION AND SERVICE SERVICE SCHEDUL SCHEDULE E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Daily Maintenan Maintenance ce Requirement Requirements. s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Weekly Maintena Maintenance nce Requiremen Requirements ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Monthly Mainten Maintenance ance Requireme Requirements nts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Quarterly Quarterly Maintenance Maintenance Requireme Requirements nts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Semi-Annual Semi-Annual Maintenance Maintenance Requireme Requirements nts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Annual Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Miscellaneous Maintenance Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Preventative Preventative Mainten Maintenance ance Checklis Checklistt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 MAINTENANCE MAINTENANCE INSTRUCT INSTRUCTIONS IONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Daily Maintena Maintenance nce Tasks Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Front Conveyor Conveyor Bearing Bearing - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Rear Conveyor Conveyor Bearings Bearings - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Auger Bearings - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Screed Vibrator Vibrator Shaft Shaft Bearings Bearings - Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 4


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TITLE

SECTION

Hydraulic Fluid - Check Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Engine Oil - Check Check Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Engine Radiator Radiator - Check Check Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Cooling Cooling Fan - Inspect Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Truck Hitch Hitch Option Rollers Rollers - Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Engine Air Air Intake Piping - Inspec Inspectt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Drive Belts Belts - Inspect Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Fuel Water Water Separator Separator - Drain Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Crankcase Crankcase Breather Breather Tube - Inspect Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Conveyor Conveyor Chains Chains - Inspect/Adjus Inspect/Adjustt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Weekly Maintena Maintenance nce Tasks Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Truck Hitch Hitch Option Slides Slides - Clean/Greas Clean/Grease e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Screed Depth Cranks Cranks - Grease Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Screed Pivot Points Points - Grease Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Front Wheel Wheel King Pins Pins - Grease Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 Front Wheel Wheel Bogie Pivot Pivot Bearings Bearings - Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Monthly Maintenance Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Parking Parking Brake - Operati Operational onal Check Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 QUARTERLY QUARTERLY MAINTENANCE MAINTENANCE TASKS TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 Engine Oil Oil and Filter Filter - Change Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 Air Cleaner - Check/Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 Short-Coupled Short-Coupled Drive Drive Shaft - Grease. Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46 Fuel Pump Pump - Check Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46 Radiator Radiator Hoses - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46 Auger/Conveyor Drive Chains - Check/Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47 Hopper Hinge Hinge Assembly Assembly - Inspection/Re Inspection/Repair pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 Auger Section - Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 SEMI-ANNUAL SEMI-ANNUAL MAINTENANCE MAINTENANCE TASKS TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49 Hydraulic Hydraulic Fluid Fluid and Filters Filters - Change Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49 Draining Draining the Hydraulic Hydraulic System System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50 Changing Changing Hydraulic Hydraulic Oil Filters Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53 Removal Removal and Cleaning Cleaning of Relief Relief (In Hydraulic Hydraulic Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54 Changing Changing Hydraulic Hydraulic System System Charge Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56 Refilling Refilling Hydraulic Hydraulic System with with Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57 Engine Coolant - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57 ANNUAL MAINTENANCE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58 Front Bogie Bogie Wheels Wheels - Repack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 Pump Drive Drive Box - Change Change Fluid Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 Auger/Conveyor Planetaries - Change Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61 Drive Wheel Wheel Planetaries Planetaries - Change Change Fluid Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62 Engine Fuel Fuel Filter Filter - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63 Changing Changing a Canister Canister - Type Fuel Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63 Changing Changing a Spin-On-Type Spin-On-Type Fuel Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65 Washdown Washdown Fuel Filter Filter - Change Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66 MISCELLANEOUS MISCELLANEOUS MAINTENAN MAINTENANCE CE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67 Adjustment of Hopper Wiper Bar s - As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 Adjustment of Swing Console - As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 Adjustment of Steering Consoles and S eats - As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69 Adjustment of Hopper Side Ext ensions - As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70 Drive Tire Servicing Servicing and and Hydroinflation Hydroinflation - As Required Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70 OFF SEASON SEASON STORAGE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70


5

TABLE OF CONTENTS

TITLE

SECTION

TROUBLESHOOTING

GENERAL GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 General General Fault Isolation Isolation Tips/Infor Tips/Information. mation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 How This This Section Section Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 General General Troubleshooti Troubleshooting ng Guidelines Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Alarms Indications and Remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 BLAW KONTROL® ULTRASONIC GRADE CONTROL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 6-6

TECHNICAL SPECIFICATION

GENERAL GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Machine Machine Identificatio Identification n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Environmenta Environmentall Specification Specifications s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Physical Physical Specificatio Specifications ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Miscellaneou Miscellaneous s Specifications Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

FUEL AND LUBRICANT SPECIFICATIONS

GENERAL GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 FLUID CAPACITIE CAPACITIES S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 HYDRAULIC HYDRAULIC OIL REQUIREMENTS REQUIREMENTS AND SPECIFICA SPECIFICATIONS. TIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 LUBRICATING OIL/GREASE (EXCEPT ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 ENGINE LUBRICATI LUBRICATING NG OIL SPECIFICAT SPECIFICATIONS IONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 DIESEL FUEL FUEL SPECIFICATIO SPECIFICATIONS NS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 HAZARDOUS HAZARDOUS SUBSTANCE SUBSTANCE PRECAUTIO PRECAUTION N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

SCHEMATICS

SCHEMATICS. SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 ELECTRICAL ELECTRICAL SCHEMATIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 HYDRAULIC HYDRAULIC SCHEMATIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

RECOMMENDED SERVICE PARTS

INDEX

WARRANTY INFORMATION

6


INTRODUCTION


1

INTRODUCTION

INTRODUCTION The purpose of this manual is to provide the operator and site maintenance personnel with knowledge of the fundamental rules and criteria to be followed for the on-site use and maintenance of the Ingersoll-Rand Blaw-Knox PF-161 Paver/Finisher. This instruction manual must be read and fully understood by the operator before operating the machine. This manual consists of: •

INTRODUCTION

•

Section 1, SAFETY

•

Section 2, ASSEMBLY

•

Section 3, OPERATING CONTROLS AND INSTRUMENTS

•

Section 4, OPERATING INSTRUCTIONS

•

Section 5, MAINTENANCE INSTRUCTIONS

•

Section 6, TROUBLESHOOTING

•

Section 7, TECHNICAL SPECIFICATION

•

Section 8, FUEL AND LUBRICANT SPECIFICATIONS

•

Section 9, SCHEMATICS

•

Section 10, RECOMMENDED SPARE PARTS

•

INDEX

Always keep this manual handy for quick reference. If any part of this manual cannot be understood, contact your supervisor or local Ingersoll-Rand Blaw-Knox Distributor. This is an essential condition for working safely with this machine. The correct machine operation, use, and regular maintenance are also essential elements to provide the highest perform ance and safety. NOTE: This manual is accompanied by an engine instruction manual provided by the engine’s manufacturer. Please follow the operation and maintenance instructions as specified in both the machine and engine manuals.

PROCEDURE WHEN RECEIVING THE MACHINE Your machine has been tested, accurately checked, and prepared for shipment . Every part of the machine, including the detached parts, has been accurately chec ked before being shipped from the factory. When you receive the machine, and before unpacking the equipment, check if damage has occurred during transport and if any parts are missing. Check the equipment by consulting the shipment documents. If goods are damaged or if parts are missing, inform the freight agent as soon as possible. They will inform you regarding how to proceed in order to make a complaint and get the damaged or missing goods replaced. 2


INTRODUCTION

IDENTIFICATION DATA An exact description of the model type and serial number of your machine will facilitate fast and efficient response from our parts and service operations. Always provide the model of your machine and its serial number when you contact the local Ingersoll-Rand Blaw-Knox service or parts office. We advise you to record your machine data in the following table to ensure that the paver/ finisher and engine information is readily available when you need it.

Table 1: Machine Identification Data MACHINE IDENTIFIER

IDENTIFYING NUMBER

Paver/Finisher Model Number Paver/Finisher Serial Number Year of Manufacture Engine Type Engine Serial Number

MACHINE IDENTIFICATION The Ingersoll-Rand Blaw-Knox PF-161 Paver/Finisher identification plate is located at 1, Figure 1 and the engine serial number can be found on its identification plate located at 2, Figure 1.

Figure 1


3

INTRODUCTION

GENERAL INFORMATION All safety rules in Section 1 must be observed. If further information is required concerning the recommended uses on PF-161 Paver/ Finisher, contact your local Ingersoll-Rand Blaw-Knox Distributor.

Ingersoll-Rand Company, Road Machinery Division Shippensburg, Pennsylvania 17257 USA Tel:

+1 - 717-532-9181 (Service and Warranty)

Fax:

+1 - 717-530-3402 (Service and Warranty)

Fax:

+1 - 717-530-3403 (Customer Service Parts)

Ingersoll-Rand reserves the right to make changes or modifications without prior notice and without incurring any liability to retrofit machines previously shipped from the factory.

MACHINE DESCRIPTION The Ingersoll-Rand Blaw-Knox PF-161 Paver/Finisher is a wheel-mounted, mid-sized paver/ finisher capable of placing bituminous base, binder and surface course mixes, cement or lime stabilized sub-base and graded aggregate materials. The PF-161 Paver/Finisher functionally consists of two sections (Figure 2). These sections are called the tractor (1, Figure 2) and the screed (2, Figure 2). First, the tractor receives, delivers and spreads the paving material in front of the screed. The tractor then, tows the screed forward over the paving material. As the screed is being towed over the paving material it levels, smooths, seals and starts the compaction process on the mat (Newly paved area).

4


INTRODUCTION The following paragraphs provide a brief description of each of the major components that make up the PF-161 Paver/Finisher. Standard components are addressed initially followed by brief descriptions of each of the available options.

Figure 2

ENGINE The PF-161 Paver/Finisher is powered by the Cummins “Elite” series, EPA certified, 4 cylinder, turbocharged diesel model 4BTA 3.9...239 cubic inch (3.92) displacement, 107 hp (80 kW) @ 2100 rpm. The engine is equipped with an oil cooler, replaceable oil filter, replaceable fuel filter, replaceable air cleaner element and a real-time hour meter located in the electrical junction box. Refer to the Cummins Engine Operation and Maintenance Manual supplied with the Paver/ Finisher for additional engine operating and maintenance procedures.

ELECTRICAL SYSTEM The PF-161 Paver/Finisher utilizes a 12-Volt, negative ground with a 105-Amp alternator for its electrical needs. Wiring is color coded, number impregnated and the harness is wrapped in polyethylene looms for maximum durability and ease of servicing. All circuits tie to circuit boards located in the operator’s swing console and are equipped with automatic reset circuit breakers.


5

INTRODUCTION

HYDRAULIC SYSTEM The PF-161 Paver/Finisher is equipped with a hydraulic system that has a 151-liter (40 gal.) reservoir capacity. Primary filtration is accomplished with 5.0 micron variable depth “Fiberglas” filters on the inlet side of each traction-drive charge pump. Secondary filtration is accomplished with 100-mesh strainers located on the suction side of the general purpose and feeder drive-pump circuits. All hydraulic circuits are routed through a central, easy access valve block equipped with interchangeable solenoid cartridge valves for maximum reliability and easy servicing.

FUEL SYSTEM The PF-161 Paver/Finisher is equipped with a 144-liter (38 gal.) fuel tank, equipped with a replaceable filter. This fuel tank provides an onboard supply of diesel fuel for the engine, heaters and the pressurized washdown system.

COOLING SYSTEM The PF-161 is equipped with a 24.6 L (26 qt.) capacity cooling system.

BRAKES The PF-161 Paver/Finisher primary braking is accomplished via the dynamics of a hydrostatic traction drive system. Hydraulic secondary parking brakes, an internal element of the planetary final drive units, can be switch actuated from either operator’s console. These spring-applied secondary parking brakes are automatically actuated when the main power switch is in the OFF position, electric power is otherwise interrupted or there is a pressure drop in the general purpose hydraulic system. Refer to Section 5 of this manual for additional Brake information.

TRACTION DRIVE The PF-161 Paver/Finisher is equipped with an independent, hydrostatic direct drive system with electric/hydraulic controlled single-speed planetaries and 2-speed motors. Speed selection is infinitely variable in each of the two speed ranges:

6

Low Range @ 2100 rpm.................................................

0 - 3.6 kph (2.2 mph)

High Range @ 2100 rpm................................................

0 - 15.9 kph (9.9 mph)


INTRODUCTION

TRACTION LOCK SYSTEM The PF-161 Paver/Finisher is equipped with an electronically controlled hydraulic version of a mechanical-locking differential. This provides a full-time tractive effort at both drive wheels with an internal pressure modulation feature between right and left-side drives to compensate for the unequal power requirement of turning.

PIVOT STEERING An electrical switch on the operator’s console hydraulically destrokes the respective right or leftside traction pump to the neutral position for power-assisted steering in confined quarters.

REAR SUSPENSION Two 14:00 X 20 low-pressure (182 to 260 kPa (25 to 35 psi)), sand rib, high-flotation tires, hydroinflated to 75%.

FRONT SUSPENSION Four steerable, 305 mm (12 in.)-wide and 559 mm (22 in.)-diameter, solid- rubber tired wheels, are mounted on a offset tandem bogie frame. Front machine weight is proportionally split 40-60% between the front and rear sets of bogies for optimum weight distribution. Tie-rod synchronized steering cylinders (one on each side) are mounted on the outside of the bogie frame for easy service access.

OPERATOR’S UMBRELLA The PF-161 Paver/Finisher is equipped with an operator’s umbrella measuring 1373 mm (54 in.) square. The umbrella comes with mounting hardware included.

TRUCK HITCH Two bearing-equipped push rollers mounted on an oscillating frame with electric/hydraulic actuated roller-equipped clamp arms quickly grip and secure a truck in proper attitude for unloading material into the machines hopper. It automatically compensates for both minor lateral and directional misalignment of the truck with the paver/finisher with no exposed secondary slide mechanisms.

Table 2: Truck Hitch Specifications CHARACTERISTIC

SPECIFICATION

Maximum Arm Opening

3302 mm (130 in.)

Minimum Arm Opening

1829 mm (72 in.)

Degree of Swivel

±8 °

Drift from Center

305 mm (12 in.) (Automatically self-centering)


7

INTRODUCTION

POWER FLOW GATES Two separately operated, electrically controlled, adjustable flow gates (2, Figure 3) meter material delivery to the augers. The gates are located in the conveyor tunnel entry at the rear hopper.

DUAL FEED SYSTEMS Separate, infinitely variable speed, hydrostatic planetary drive for right and left-side feed systems provide optimum auger/conveyor operation throughout the machine’s entire capability range. Right and left-side systems function independently and operation is controlled either manually with electrical switches or automatically by electrical sensing elements positioned at the outer end of each auger. Manual electri cal switches are positioned on the tractor operator’s swing console and on the screed control consol es. Maintenance-free auger/conveyor bearings combine an exclusive patented seal with a new synthetic hydrocarbon lubricant to eliminate the daily greasing requirement.

Figure 3

8


INTRODUCTION

CONVEYORS Conveyor assemblies (1, Figure 3) consist of solid bars riveted to special, heat-treated steel, offset link R2 (rapid -repair), heavy-bushed roller chain riding on forged steel sprockets. Conveyor floor plates and rear wrap plates are constructed of abrasion-resistant QT steel with a Brinell hardness range of 360 to 440 throughout the entire plate thickness.

Conveyor Tunnel Opening..............................................

1362 mm (53.625 in.)

Conveyor Floor Plate Thickness.....................................

10 mm (375 in.)

AUGERS Augers (1, Figure 4) consists of replaceable, high alloy, cast steel hemi-screw sections. Augers are adjustable in height hydraulically by simply actuating an electrical switch.

Table 3: Auger Specifications CHARACTERISTIC

SPECIFICATION

Auger Diameter

356 mm (14 in.)

Auger Flight Thickness

16 mm (5/8-in.)

Auger Height Adjustment (above grade)

114-279 mm (4.5 - 10.5 in.)

Figure 4


9

INTRODUCTION

AUTOMATIC FEED CONTROL SYSTEM The PF-161 Paver/Finisher is equipped with a Mat Kontrol ® II to control the operating speed of the dual feed systems. This system is supplied with a choice of either Paddle Sensors or Ultra 3s® (Ultrasonic Sensing System) Sensors. The following paragraphs provide a brief explanation of each sensor system.

MAT KONTROL ® II WITH PADDLE SENSORS An electric/hydraulic control arrangement that automatically controls both the on-off action and infinitely variable operating speed of the dual feed systems. Paddle Sensors are mounted at the outer end of each auger. From these locations, they monitor the volume of material in front of the screed via actual contact with the material. As these paddles detect the level of material present, they will actuate the feeder drives as necessary and either cause an increase or decrease of conveyor speed or even start and stop the conveyor(s), as appropriate, to maintain a consistent volume of material to the screed.

MAT KONTROL ® II WITH ULTRA 3s® SENSORS An electric/hydraulic control arrangement that automatically controls both the on-off action and infinitely variable operating speed of the dual feed systems. The Ultra 3s ® sensors are positioned at the outer end of each auger. From these positions, they monitor the volume of material in front of the screed and control the feeder drives, as necessary, to maintain a consistent volume of material to the screed. Unlike the paddle system described above, the Ultra 3 s® system makes no actual physical contact with the material. Instead, it works very similar to an active sonar system, as it sends sound pulses to the material in front of the screed and waits for a bounce-back or echo. Accurate measurement of the resulting time delay between output pulse and the returning echo results in a level of accuracy rivaling mechanical means such as paddles. This system is much less vulnerable to heat and abrasions than the paddle system since it has no physical contact with the material.

SMOKE-EATER ® VENTILATION CONTROL SYSTEM This is a machine-mounted heat and fume extraction system that provides a cleaner, cooler and more environmentally friendly work area for the machine’s operator and screedman. The system is provided standard on all machines manufactured for domestic use. The system consists of a single, hydraulically-driven, high-volume fan and two collector hoods. The system gathers heat and fumes from the paver’s auger and screed area and disperses them into the atmosphere away from the operators via a single, deck-mounted exhaust stack. The exhaust stack folds down to minimize transport height of the machine. A 3-position switch controls the system. The three positions of this switch are; “ON” (constant system operation), “AUTO” (system operates only when the paver is in motion), and “OFF” (the system does not operate). A vacuum sight switch is incorporated into the fan intake plenum to permit visual monitoring of the system for proper operation.

10


INTRODUCTION

WASHDOWN SYSTEM A pressurized diesel fuel washdown system with a 10.7 m (35 ft.) hose and spray valve nozzle (2, Figure 5) is mounted on a self-storing, spring-retracting hose reel. Pressurization of the washdown hose is controlled via a washdown hose pump switch (1, Figure 5).

Figure 5

CONTROLS The dual control stations (right and left side) are each equipped with an operator’s seat (2, Figure 6) and a direction/speed control pedestal (1, Figure 6). A common, center-mounted, swing console (3, Figure 6) with position lock, provides both control stations with electrical switch control of the main power, starter, throttle, horn, shifting of traction-drive motors, right and left-side feed system function, screed lift, auger lift, folding hopper, flow gates, screed vibrator function, parking brake, traction lock system, pivot steering, optional truck hitch and optional front-wheel power assist. The screed vibrator frequency/amplitude, feed system speed, flow gate override, powered screed functions and mat depth are all controlled from the screed control boxes (4, Figure 6). The swing console also contains the tachometer/hour meter and analog gauges for engine oil pressure, water temperature, voltmeter and hydraulic oil temperature. Warning lights are also included for “Brake On”, “Change Hydraulic Filter” and “Low Material” for units equipped with optional material indicators.


11

INTRODUCTION Refer to the Section 3, OPERATING CONTROLS AND INSTRUMENTS of this manual for a complete description of the Operator’s Consoles, Controls and Instruments.

Figure 6

SCREED CHOICES/SCREED OPTIONS The following paragraphs briefly describe the various screed choices and screed options that may be on your machine.

SCREED HEATERS All Blaw-Knox screeds offer screed heating options. Your machine will contain one of the following screed heater systems.

DIESEL ONLY HEATERS These heaters are unitized, diesel-fueled, SureFire ® burner/blowers. Each unit contains a manual switch-activated spark igniter. A built-in timer controls the fuel pump which supplies diesel fuel to the screed heaters and the washdown system to provide an infinitely variable 15-30 minute run cycle time. Run cycle time is limited in this way to protect the pump from accidental extended operational misuse which could result in premature pump failure.

12


INTRODUCTION

DIESEL HEATERS WITH AUTOMATIC TEMPERATURE AND IGNITION CONTROL (ATIC) These heaters are unitized, diesel-fueled, SureFire ® burner/blowers. Each unit is equipped with Automatic Temperature and Ignition Control (ATIC). This ATIC system automatically ignites the heaters to preheat and maintain the temperature of the screed plate within 8° C (14° F) range of any preselected temperature within the system’s operating range capability of 80° to 177° C (175° to 350° F). The ATIC system incorporates flame failure and hightemperature shutdown safety features.

PROPANE (LPG) HEATERS WITH ATIC These heaters are unitized, diesel-fueled, SureFire ® burner/blowers. Each unit is equipped with Automatic Temperature and Ignition Control (ATIC). This ATIC system automatically ignites the heaters to preheat and maintain the temperature of the screed plate within 8° C (14° F) range of any preselected temperature within the system’s operating range capability of 50° to 160° C (125° to 320° F). The ATIC system incorporates flame failure and hightemperature shutdown safety features. This option includes a propane bottle mount, pressure regulator valve and connector tubing. This option does not include the propane bottle itself.

WEDGE-LOCK ® SCREED The Wedge-Lock ® Screed is a basic 2.44 m (8 ft.) fixed width, vibratory screed. The screed contains a one-piece 623 mm (24.5 in.) wide x 13 mm (0.5 in.) thick, bolt-on replaceable, abrasion-resistant, alloy-steel screed plate. The screed also comes equipped with springloaded MatStop ® edger plates with replaceable wear shoes, edger guides and cut-off plates. Bevel edger plates are optional. A center crown kit is available with the Wedge-Lock ® Screed. This mechanical, dual crown kit provides simultaneous adjustment of center lead and tail crown from 76 mm (3 in.) positive to 19 mm (3/4 in) negative. Below is a list of the Wedge-Lock ® Screed specifications.

Table 4: Wedge-Lock ® Screed Specifications CHARACTERISTIC

SPECIFICATION

Standard Paving Range (with cut-off plates)

1.83 - 2.44 m (6 - 8 ft.)

Maximum Paving Width

5.79 m (19 ft.)

Paving Depth Range

6 - 203 mm (0.25 - 8 in.) Optional to 305 mm (12 in.)

Vibrator Speed

0 - 3100 vpm (52 Hz)


13

INTRODUCTION

WEDGE-LOCK ® SCREED EXTENSIONS Wedge-Lock ® screed extensions are used to increase paving width. These extensions to the basic screed are available in 152 mm (6 in.), 305 mm (12 in.), 610 mm (24 in.) and 914 mm (36 in.) lengths. They may be supplied either in kit form or individually. Various options correspond to specific extension sizes. Table 5 below provides a list of these extensions and the features available for each.

Table 5: Wedge-Lock ® Screed Extensions Size and Options Available Options Size Vibration

Heat

Center Crowning Capable

152 mm (6 in.) 305 mm (12 in.)

xx

610 mm (24 in.) 914 mm (36 in.)

xx xx

xx

2.5/5B HYDRAULIC SCREED EXTENSIONS Optional, hydraulic telescoping extensions with replaceable screed plates mount on either a basic or extended Wedge-Lock ® Screed to permit increased paving width of up to 762 mm (2.5 ft.) on either or both sides of the screed, while continuing to pave. Slope control on each extension is accomplished manually up to a maximum 25 mm (1 in) in 305 mm (12 in.) positive in any extended width up to 25 mm (1 in.) in 305 mm (12 in.) negative fully extended. An additional 305 mm (12 in.) modular extension can be installed on the outer end of either or both 2.5/5B extensions to increase paving width up to a maximum of 4.57 m (15 ft.).

POWER SLOPE OPTION FOR 2.5/5B HYDRAULIC EXTENSIONS This is an electrically actuated power sloping arrangement with visual sight gauges which replaces the standard mechanical sloping mechanism. This option provides for effortless on-the-go slope control of each extension relative to the main screed up to 25 mm (1 in.) in 305 mm (12 in.) positive at any extended width and up to 25 mm (1 in.) in 305 mm (12 in.) negative fully-extended. Slope control switches are located on the screed control consoles.

14


INTRODUCTION

BERM ATTACHMENT OPTION FOR 2.5/5B HYDRAULIC EXTENSIONS This option replaces the standard screed plate arrangement to provide up to 102 mm (4 in.) of vertical rise in 610 mm (24 in.) at the outer edge of each extension. The addition of this option provides the means to form water drainage channels up to 610 mm (24 in.) in from the edge of the mat, reducing the need for curbing.

OMNISCREED ® IA This is a basic 2.44 m (8 ft.) power extendible, vibratory screed providing infinitely variable onthe-go-paving width flexibility with uniform compaction and surface texture across the entire mat width. The main screed and both independent, front-mounted, hydraulically extendible sections are equipped with vibrators and bolt-on replaceable, abrasion resistant QT Steel screed plates. These plates are 457 mm (18 in.) wide on the main screed and 356 mm (14 in.) wide on the extendible sections. All plates are 13 mm (0.5 in.) thick. Spring-loaded MatStop ® edger plates with replaceable wear shoes, edger guides and cut-off plates are included. Bevel edger plates are optional. Below are the specification details for the OmniScreed ® IA.

Table 6: OMNISCREED ® Specifications CHARACTERISTIC

SPECIFICATION

REMARKS

Standard Paving Width

1.83 - 4.0 m (6 - 13.5 ft.)

With cut-off plates


5.23 m (17 ft., 2 in.)

With optional Wedge-Lock ® extensions

Paving Depth Range

6 - 203 mm (0.25 - 8.00 in.)

Optional to 305 mm (12 in.)

Vibrator Speed

0 - 2500 vpm (42 Hz)

Center Crown

76 mm (3 in.) positive - 19 mm (0.75 in.) negative

Choice of either mechanical or hydraulic-powered dual crown kits to simultaneously adjust center lead and tail crown.

Extension Power Slope Range

25 mm (1 in.) in 305 mm (12 in.) positive

For any extended width (0 to 8%) Diesel or propane-fueled

Heat


2 main burners and 1 on each extendible section

SureFire® burner blowers. Each unit contains an individual switch-activated ingniter and provides fast even heat over the entire screed base regardless of the extendible section position.

15

INTRODUCTION

GENERAL EQUIPMENT OPTIONS The following paragraphs provide brief explanation of the general options that are available and may be present on your PF-161 Paver/Finisher. These options do not fall under any particular category as did the screed options discussed earlier.

Front Wheel Power Assist Option This is a separate, constant torque, hydrostatic-drive arrangement for the rear set of front bogie wheels. It provides up to 20% more tractive effort in the machine’s paving speed range.

Material Indicator Kit Option This kit consists of electrical sensing elements that when mounted on the flow gates audibly warn the paver/finisher operator when material level drops below a preset level at the conveyor tunnel entry.

Blaw-Kontroll ® II Option This option is an extremely accurate, electronic grade-and-slope control system. It automatically maintains the elevation and transverse (side-to-side) slope of a paver/finisher’s screed to preset specification parameters, with respect to a single reference. This is accomplished by controlling the machine’s hydraulic system. The system can also be set up to control the elevation of each side of the screed with respect to grade by referencing from both sides of the paver/finisher simultaneously. The system will sense and correct for deviation in grade elevation as small as 0.127 mm (0.005 in.) when using the standard Blaw-Knox mechanical-grade sensor. Slope resolution is 0.005%.

16


INTRODUCTION UltraEye ® V Grade Sensor Option This option is an ultrasonic “non-contacting” grade sensor for the Blaw-Kontrol ® II system. This option is directly interchangeable with the standard mechanical-grade sensor. This sensor provides a resolution of 0.508 mm (0.020 in.).

Automatic Level Control (Also Known as a Joint Matcher) Option This is an electric/hydraulic control system that automatically controls the elevation of the mat being placed on one side of the paver/finisher with respect to a reference surface such as an adjacent mat or curb. This option is also available in sets (2 each) to control mat elevation on both sides of the machine simultaneously. The resolution of this system is 3.175 mm (0.1259 in.).

Floating Beam Reference Option This option is used as a sensing reference for a Blaw-Kontrol ® II Control System. It accurately averages longitudinal irregularities in the grade over which paving is being performed. This eliminates the expense of installing and maintaining stringline references. It is available in 6.10 m (20 ft.), 9.14 m (30 ft.) and 12.20 m (40 ft.) lengths and in sets (2 each) for dual grade referencing.

Mat Reference Option This is a 6.10 m (20 ft.) rear-mounted aluminum beam riding on eight (8) sets of spring-loaded dual road wheels with the aluminum bridge and hardware required to match it to a 9.14 m (30 ft.) front-mounted floating beam. This produces a 16.77 m (55 ft.) mobile-grade referencing system.

Additional Operator’s Umbrella Option This is a 1372 mm (54 in.) square umbrella with mounting hardware supplemental to the standard single unit to accommodate the second operator’s control station.


17

INTRODUCTION

IDENTIFICATION OF MAJOR COMPONENTS Figure 7 4

5

3

6

2

7

1

8

10 9

Legend:

18

1.

Hopper

6.

Seat

2.

Conveyor

7.

Screed

3.

Flow Gates

8.

Screed Tow Point

4.

Direction/Speed Lever Control Pedestal

9.

Front Wheel Bogies

5.

Main Console

10.

Rollers


SECTION 1 - SAFETY


1-1

Section 1

SAFETY

SAFETY BE AWARE OF SAFETY INFORMATION This is the Safety Alert Symbol. When you see this symbol in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices.

UNDERSTAND SIGNAL WORDS A signal word - DANGER, WARNING, or CAUTION - is used with the safety-alert symbol. Signal words are categorized and used in a strict hierarchy of seriousness, depending on the nature of the hazard and whether or not it is life threatening to personnel, injurious to pers onnel or potentially damaging to property, equipment or could have an adverse effect on the machines ability to perform in an efficient manner. DANGER, WARNING, or CAUTION safety labels may be located near specific hazards, and are also used in this manual to alert the reader to specific hazards - as defined below.

This is the SAFETY ALERT SYMBOL. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

!

DANGER

DANGER is used to indicate the presence of a hazard which will cause severe personal injury or death if the warning is ignored.

(Red Background)

!

WARNING

WARNING is used to indicate the presence of a hazard which can cause severe injury or death if the warning is ignored.

(Orange Background)

!

CAUTION

CAUTION is used to indicate the presence of a hazard which will or can cause personal injury, or property damage if the warning is ignored.

(Yellow Background)

NOTICE

NOTICE is used to notify people of installation, operation, or maintenance information which is important but not hazard related.

(Blue Background)

1-2


SAFETY

Section 1

OVERVIEW Before you operate, maintain, or in any other way use this Paver/Finisher: READ and STUDY this manual. KNOW how to safely use the paver/finisher’s controls and what you must do for safe maintenance. ALWAYS wear or use proper personal protec tive equipment required for your person al protection. If you have ANY QUESTIONS about the safe use or maintenance of this paver/finisher, ASK YOUR SUPERVISOR OR CONTACT ANY INGERSOL-RAND DISTRIBUTOR. NEVER GUESS-ALWAYS CHECK!

WARNINGS The following conventions are used in this manual to designate instructions of particular importance. NOTE: Refers to special information on the efficient use of the machine. NOTICE: Denotes special nonhazardous related information. CAUTION: Refers to orders and prohibitions directed towards preventing product/property damage and/or degraded machine performance. WARNING: Refers to orders and prohibitions designed to prevent personal injury and/or death.

GENERAL Ingersoll-Rand cannot foresee all possible circumstances that might lead up to a potential hazard. Therefore, the combination of warnings listed in this manual and those placed on the machine itself are not intended to be all inclusive. Operators and maintenance personnel must be alert to recognize and avoid potential hazards. They should also have comprehensive training, required skills and necessary too ls to properly perform their functions. The machine was built in accordance with state-of-the-art standards and recognized safety rules. Nevertheless, its misuse or careless operation may constitute a life-threatening risk to the user or to third parties and may cause damage to the machine or other material property. The machine must be used only as described in the operating and control sections of this manual. The machine must only be operated by safety-conscious persons who have been properly trained in operating the machine and are fully aware of the safety issues associated with its operation. Any functional disorders, especially those affecting the safety of the machine, must be corrected immediately.


1-3

Section 1

SAFETY

The machine is designed exclusively for the Pave/Finish of asphaltic road construction materials. Use of the machine for purposes other than that mentioned, such as towing other vehicles/equipment is considered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user. Operating the machine within the limits of its designated use also involves compliance with the inspection and maintenance directives contained in the operating section of this manual.

SELECTION AND QUALIFICATION OF PERSONNEL Work on and with the machine must be performed by qualified personnel only. Statutory minimum age limits must be observed. Individual responsibilities of the personnel responsible for operation, setup, maintenance and repair of the machine should be stated clearly. Define the machine operator’s responsibilities: not only pertaining to the machine’s operation, but also with regard to observing traffic regulations. The operator should have the authority to refuse instructions by third parties that are contrary to safety. Do not allow persons being trained or instructed in the operation or maintenance of the machine to work without permanent supervision by an experienced person. Work on the electrical system and equipment of the machine must be done only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electric ian and must be in accordance with electrical engineering rules and regulations. Work on the chassis, brake, hydraulic and steering systems must be performed by skilled personnel with special knowledge and training for such work.

ORGANIZATIONAL MEASURES Operation and Maintenance manuals MUST alw ays be available at the site where the mac hine is used. OBSERVE AND INSTRUCT the user in all other generally applicable legal and mandatory regulations relevant to accident prevention and environmental protection. These compulsory regulations may also deal with the handling of haz ardous substances, issuing and/or w earing of personal protective equipment, and traffic regulations. SUPPLEMENT operating instructions with detailed working instructions pertaining to the specific work location. ALWAYS be sure that persons entrusted with work on the machine have read the operating instructions and, in particular, the chapter on safety before beginning work. Reading the instructions after work has begun is too late. This is especially important f or persons who work only occasionally on the machine, e.g. during set up or maintenance. MAKE CERTAIN personnel are working in compliance with the operating instructions and are alert to risks and safety factors.

1-4


SAFETY

Section 1

ALWAYS tie back or otherwise secure long hair, wear close-fitting garments and avoid wearing jewelry such as rings, bracelets and necklaces. Injury may result from clothing, hair, or jewelry being caught up in the machinery. USE protective equipment wherever required by the circumstances or by law. OBSERVE all safety instructions and warnings attached to the machine and in this manual. BE SURE all safety instructions and warnings attached to the machine are complete and perfectly legible. STOP the machine immediately in the event of any malfunction. REPORT the malfunction to the proper authority/person. The continued operation of a machine that is not working properly may cause extensive damage to the machine or significantly increase the hazards to operating personnel from abnormal operating conditions. NEVER provide service or maintenance to the machine in ANY manner other than that which is described in this manual. NEVER make any modifications, additions or conversions to the machine which might affect safety without the manufacturer’s approval. This applies to the installation and adjustment of safety devices and valves as well as to welding work on load bearing elements. ALWAYS ADHERE to prescribed intervals or t hose specified in the operating instruct ions for routine checks and inspections. Consistently performing scheduled maintenance will extend the life of your machine.

MANDATORY SAFETY MEASURES Never clean, lubricate or service the paver/finisher when it is running. Always operate the SmokEater ® Ventilation Control System when placing paving materials which produce fumes. Do not operate the machinery while under the influence of drugs or alcohol. Use safety items (hard hat, safety boots, eye and ear protection, etc.) as appropriate or required. Do not wear radio or music headphones while operating the machines. Do not wear jewelry while operating the machine. Re-install safeguards and shields securely and clear all maintenance t ools before starting the engine after maintenance. If you have ANY QUESTIONS about the safe us e or maintenance of this machine, ASK YOUR SUPERVISOR OR CONTACT ANY INGERSOLL-RAND BLAW-KNOX DISTRIBUTOR. NEVER GUESS-ALWAYS CHECK! Failure to adhere to these instructions may result in serious injury or even death.


1-5

Section 1

SAFETY

LOADING AND UNLOADING Loading Dock with Ramp (Preferred Method) The easiest and safest method for unloading your Ingersoll-Rand Blaw-Knox PF-161 from a truck is to drive it off onto a loading dock that is level with the truck bed. Before unloading: •

Remove any loose parts from the truck deck or machine.

•

Release and remove any tie-down equipment, and chocks and blocks under the machine frame.

•

Position the rear of the trailer firmly against the loading dock.

•

Engage the truck’s parking brake.

Alternate Ramp Method If a loading dock is not available, a ramp or set of ramps positioned at a 12° angle may be used. Ramp(s) must be rated to support the weight of the machine, 18T (20 tons). •

Remove any loose parts from the truck deck or machine.

•

Release and remove any tie-down equipment, and chocks and blocks under the machine frame.

PRE-START INSPECTION INSPECT your paver/finisher daily. Ensure that the routine maintenance and lubrication are being dutifully performed. Have any malfunctioning, broken, or missing parts repaired or replaced before use. Refer to the Maintenance Schedule located in Section 5 of this manual. VERIFY that all instruction and safety labels are in place and readable. These instructions are as important as any other equipment on the p aver/finisher. Refer to the decal location draw ing later in this Section. BE MINDFUL of your surroundings before fueling. NEVER fill the fuel tank with the engine running, while the machine is located near an open flame or while operating personnel are smoking. Smoking is PROHIBITED within 15 M (50 FT.) of the machine while fueling. ALWAYS wipe up any spilled fuel. CHECK the Front Wheel assist relief pressure. It should be set according to the operating surface. CHECK for any maintenance and repair WARNING tags placed on the machine. DO NOT operate the paver/finisher until repairs have been made and the WARNING tags have been removed by authorized personnel. KEEP the operator’s platform CLEAN. REMOVE any dirt, debris or foreign material from the operator’s platform to reduce the danger of slipping. KNOW the location of the Emergency Shut-Down Control.

1-6


SAFETY

Section 1

ALWAYS know the capabilities and limitations of your equipment in terms of speed, gradeability, steering and braking. BE AWARE of the dimensions of your paver/finisher-height and weight-as well as your screed extension’s dimensions and weight or height and dimensions of the operator’s umbrella. CHECK for any operating conditions that could be dangerous such as holes, banks, underground culverts, manhole covers, water melt pits, curbs and/or street boxes. CHECK the Parking Brake on flat open ground. Low speed range (Low Motor Shift Switch position) should not overpower the brake. If the Parking Brake can be overpowered, brake packs inside of the final drive planetaries must be repaired. Parking Brake is not adjustable.

SAFETY INSTRUCTIONS GOVERNING OPERATION AVOID any operational mode or procedure t hat might sacrifice safety. TAKE all necessary precautions to ensure that the machine is used only when in a safe and reliable condition. OPERATE the machine only if all protective and safety oriented devices, such as removable safety devices, emergency shut off equipment, soundproofing elements and exhausts, are in place and fully functional. CHECK the seat belt regularly for wear or damage. Inspect the belt hardware and fabric. Replace if the hardware is damaged or strap is nicked, frayed or loose stitching is found. START the machine from the driver’s seat only and FASTEN the seat belt before starting the engine. WATCH the indicators during start up and shutdown procedures in accordance with the operating instructions. Refer to the lamp/indicator light check procedures in the Section 5 of this manual. CHECK the surrounding area for pedestri ans. MAKE SURE no one is at danger or risk before starting up or setting the machine in motion. CHECK that braking, steering, signalling and lighting systems are fully functional before starting work or traveling with the machine. CHECK that accessories have been safely st owed away before setting the machine in motion. OBSERVE the valid traffic regulations when traveling on public roads. ALWAYS MAKE SURE the machine is in a condition compatible with these regulations. ALWAYS SWITCH ON the lighting system in conditions of poor visibility and after dark. MAKE SURE there is sufficient clearance when crossing underpasses, bridges and tunnels or when passing under overhead lines.


1-7

Section 1

SAFETY

ALWAYS KEEP at a safe distance from the edges of building pits and slopes. AVOID any operation that might be a risk to machine stability. ALWAYS SECURE the machine against inadvertent movement and unauthorized use before leaving the driver’s seat. NEVER SHIFT the transmission on a grade without first stopping the machine and applying the parking brake

Starting ALWAYS USE hand rails and steps to get on and off the Paver/Finisher. ALWAYS MAINTAIN a “three-point contact” when climbing onto or off of a Paver/Finisher. READ and FOLLOW ALL instruction decals. ALWAYS be seated with the seat belt on when operating the machine. BEFORE attempting to start the engine, ENSURE that the DIrection-Speed lever is in the NEUTRAL position. START the engine from the operator’s position only. NEVER jump start the machine directly to the starter or starter solenoid. SEVERE INJURY or even DEATH could result from the machine lurching forward or reverse and running over the person(s) attempting to jump start the machine. AVOID personal INJURIES by making sure that the machine being jumped does not touch or come in contact wit h the machine supplying the jump. NEVER jump a frozen battery, it will EXPLODE. While charging lead acid batteries generate explosive gases. Keep SPARKS, FLAMES and lighted SMOKING material AWAY from BATTERIES. ALWAYS wear safety glasses when working near batteries. Proceed as follows when jump starting the machine:

1-8

•

Connect the Positive (+) terminal of the booster battery to the Positive (+) terminal of the discharged battery.

•

Connect the Negative (-) terminal of the booster battery to the best ground point on the machine away from the battery.

•

Follow all the recommended engine starting procedures.

•

Remove the jumper cables in the reverse order of their connection as soon as the engine has started.


SAFETY

Section 1

Operating ALWAYS make sure that no perso n or obstruction is in your line of travel before starting to move the PAVER/FINISHER machine. ALWAYS LOOK in all directions BEFORE c hanging your direction in travel. NEVER CLIMB onto or off of the machine at any time while it is operating/running. ALWAYS remain seated with your s eat belt on when operating the paver/finisher. NO EXCEPTIONS. ALWAYS USE EXTREME CAUTION and be very observant when operating in close quarters or congested areas. KNOW and USE the hand signals required for particular jobs and know who has the responsibility for signaling. NO RIDERS. NEVER carry passengers. NEVER allow anyone to stand within the paver/finisher “articulation area” with the engine running. KNOW the area in which you are working. Familiarize yours elf with work site obstructions and any other potential hazards in the area. When the SmokEater® Ventilation Control System exhaust stack is installed, never attempt to pass under low overhead obstructions, such as bridges or utility wires, without first confirming there is adequate clearance. Always lower or remove the exhaust stack if there is any quest ion about clearance. READ and FOLLOW ALL instruction decals.

Stopping ALWAYS park the paver/finisher on solid level ground. If that is not practical, park the paver/ finisher at a right-angle to the slope and chock the wheels. Reduce the travel speed by moving the Direction Speed Levers before stopping the machine. To stop the machine, push the Direction-Speed Lever back to NEUTRAL. Push the Main Switch OFF. The parking brake will automatically engage. Before leaving the operator’s seat, ALWAYS BE SURE that all control switches are in the OFF or NEUTRAL position and the engine is shut off. Before leaving the operator’s seat MAKE CER TAIN that the hopper wings are lowered and the screed is lowered or secured in the raised position. ALWAYS mount and dismount the machine from the rear using the walkways, steps and handrails provided. Never jump from the operators platform to the ground. ALWAYS maintain a “three-point contac t” when climbing onto or off of the paver/finisher. USE proper flags, barriers and warning devices to warn others of your presence, especially when parking in heavy traffic.


1-9

Section 1

SAFETY

Maintenance In any work concerning the operation, conversion or adjustment of the machine and its safety oriented devices or any work related to maintenance, inspection and repair, always observe the start up and shutdown procedures set out in the operating instructions and the informat ion on maintenance work. ENSURE that the maintenance area is adequately secured as outlined below. If the paver/finisher is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by: •

locking the principle control elements and removing the ignition key and/or

•

rotating the battery master switch to “OFF” and attaching a warning sign to the battery master switch.

Before starting any work, check the de-energized parts for the presence of power and ground or short circuit any parts found to contain residual power in addition to insulat ing adjacent live parts and elements. The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately. CARRY OUT maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movement. ALWAYS USE the correct tools and workshop equipment when perf orming maintenance to the machine. KEEP all standing surfaces free from mud, dirt, snow and ice. CLEAN the machine, at the end of each workday while the machine is still warm with diesel fuel, kerosene or other appropriate (biodegradable) cleaning solution. All residual asphalt materials should be removed from the paver, especially in the material handling areas and the surfaces sprayed to eliminate any remaining residue. This leaves a petroleum film on surfaces to reduce the potential for materi al sticking the next time the paver is used. SPECIAL CARE MUST BE TAKEN with the engine and battery area so that cables and/or hoses are not damaged or disconnected. After cleaning, EXAMINE all f uel and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. REPAIR or REPLACE defective parts immediately. ALWAYS TIGHTEN any screwed connections that have been loosened during maintenance and repair. ENSURE that all consumables and replaced parts are disposed of safely and with minimum environmental impact. Any safety devices removed during setup, maintenance or repair purpose MUST BE refitted and CHECKED immediately upon completion of the maintenance and repair. AVOID, whenever possible, servicing, cleaning, or examining the paver/finisher with the engine running. AVOID, whenever possible, servicing or providing maintenance unless the machine is adequately secured against movement.

1-10


SAFETY

Section 1

NEVER fill the fuel tank with the engine running. Do not permit sparks, open flames or smoking within 15 M (50 ft.) of the machine while refueling. Never refuel the machine with the screed heaters operating. ALWAYS wipe up any spilled fuel. DO NOT alter the engine’s governor settings from those indicated in the engine manual and the engine option plate. ALWAYS replace damaged or lost decals. It is dangerous to operate the machine without these decals. Refer to the parts manual for the proper location and part number for all decals. In order to ENSURE the SAFE OPERATION, optimum performance and to PROTECT your WARRANTY, use only genuine Ingersoll-Rand replacement parts. DISCONNECT the battery cables when working on the electrical system or when welding on the machine. BE SURE the battery area is well ventilated (clear of fumes) should it be necessary to connect a jump battery or battery charger. Fumes from the battery can ignite by a spark and explode. BE SURE the battery charger is “Off” when making the connections if battery charging is required. The electrical equipment of machines is to be INSPECTED and CHECKED at regular intervals. Defects such as loose connections or scorched cables MUST BE RECTIFIED IMMEDIATELY. Welding, flame cutting and grinding work on the machine SHOULD ONLY BE DONE if expressly authorized, as there may be a risk of explosion and fire. Before beginning welding, flame cutting and grinding operations, clean the machine and its surroundings from dust and other flammable substances and make su re that the premises are adequately ventilated (risk of explosion). Hydraulic hose assemblies must be visually inspected at regular intervals and immediately replaced if they show signs of chafing, cracking brittleness, deformation, blistering, leakage, fitting separation, corrosion or other damages which may affect their function and strength. Do not work on hydraulic lines while the engine is running and the system is under pressure. The hydraulic fluid remains under pressure long after the engine has been stopped. Do not work on any hydraulic hose or fitting until the pressure has been relieved correctly. Hot hydraulic fluid will cause severe burns. Wait for fluid to cool down before disconnecting lines. NEVER USE YOUR HANDS to check for hydraulic leaks when inspec ting a hydraulic system. Use a piece of cardboard an always wear gloves and eye protection. Fluid penetration from a pin hole leak can cause severe injury or death. Get immediate treatment if fluid has been injected under your skin. DEPRESSURIZE ALL SYSTEM SECTIONS and pressure pipes (hydraulic system, compressed air system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work. Hydraulic lines MUST BE laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.


1-11

Section 1

SAFETY

When handling oil, grease and other chemical substances, OBSERVE the product related safety regulations. ENSURE that all consumable and replaced parts are disposed of safely and within environmental regulations. Work on the electrical system and equipment of the machine must be done only by a skilled electrician or by instructed person under the supervision and guidance of a skilled electrician and must be in accordance with electrical engineering rules and regulations. If provided for in the regulations, the power supply must be cut off to parts of machines, on which inspection, maintenance and repair work is to be carried out. Be careful when handling hot consumables (risk of burning or scalding), and wear the appropriate personal protective equipment.

HAZARDOUS SUBSTANCE PRECAUTION The following information is provided to assist the owners and operators of Ingersoll-Rand Blaw-Knox machinery. Further information may be obtained by contacting your Ingersoll-Rand Blaw-Knox Road Machinery Equipment Distributor. The following substances are used in t he manufacture or produced during the operation of this machine and may be hazardous to health if used incorrectly.

SUBSTANCE Hydraulic Oil

Avoid ingestion, skin contact and breathing fumes.

Engine Lubricating Oil


Engine Fuel


Anti-Freeze


Rust Preventative


Electric Motor Dust (Brushes/Insulation) Battery Electrolyte Engine Exhaust Fumes

1-12

PRECAUTION

Avoid breathing dust during maintenance. Avoid ingestion, skin contact and breathing fumes. Avoid breathing. Avoid buildup of fumes in confined spaces.

Paving Mixtures


Preservative Grease


SAE Gear Oil



SAFETY

Section 1

WARNING OF SPECIAL DANGERS When working with the machine, maintain a safe distance from overhead electric lines. If the work is to be carried out close to overhead lines, the work equipment m ust be kept away from them.

WARNING

! Electrocution Hazard.

If your machine comes in contact with electric power lines, observe the following: •

Stay in the operators seat.

•

Warn other workers to stay away and do not touch any control or any part of the machine.

•

If contact can be broken, drive the machine away from the danger zone.

•

If contact cannot be broken, stay in the operators seat until told that power is off. Failure to observe this admonishment could result in electrocution and death.

!

CAUTION

Equipment/Property Damage. Remove the exhaust stack if you have any doubts that it cannot pass under electrical lines or under an overpass or bridge. Failure to adhere to this admonishment could result in damage to the paver/finisher and surrounding property. Operate internal combustion engines and fuel operated heating systems only in adequately ventilated areas. Before starting the machine in enclosed areas, make sure that there is sufficient ventilation. The following table provides a list of locations and quantities of labels used on the paver/ finisher. Use this table in conjunction with the illustrations on the following pages to visualize where each label should be on the machine. It is your responsibility to maintain these labels in a legible condition on the machine.


1-13

Section 1

SAFETY Figure 1-1

1-14


SAFETY

Section 1

NO.

DECAL

NO. REQ’D

LOCATION

1

CAUTION: Auto Brakes

2

Control Console

2

CAUTION: Before starting or leaving Instructions

2

Control Console

3

WARNING: Travel Speed Shift

2

Control Console

4

WARNING: California Proposition 65 Warning

2

Hood Arrangement

5

WARNING: Avoid personal injury or death

1

Rear, under the seats

6

WARNING: Hot oil

1

Platform, near console base

7

WARNING: Avoid possible injury from runaway machine

2

Operators’ seat or Hood Arrangement

8

WARNING: Personal injury due to:

1

Hopper, front L & R side

9

WARNING: Cause of toxic fumes

2

Hopper, front L & R side

10

WARNING: Brake release, emergency towing

2

Steering Column or hood arrangement

11

WARNING: Do not close the brake release valve

1


12

WARNING: Keep from falling off platform

2

Direction-Speed Lever Console, outside low, L & R side

13

CAUTION: Operation precautions

1

Rear, under the seat next to #17

14

WARNING: Hopper injury

2

Rear, upper part of hopper, outside.

15

CAUTION: NO SMOKING

2

Rear, side under seat

16

WARNING: Hydraulic tank

1

Platform, near console base

17

WARNING: Slip and fall

1



1-15

Section 1

1-16

SAFETY


SAFETY


Section 1

1-17

Section 1

1-18

SAFETY


SECTION 2 - ASSEMBLY


2-1

Section 2

ASSEMBLY

ASSEMBLY GENERAL A Paver/Finisher shipped for us e within the United States is normally shipped nearly assembled for basic paving widths. Before paving can actually begin, some assembly must be performed. The amount of assembly required depends on the number of options you plan to use with your paver/finisher. This section provides assembly guidelines to be used during this assembly process. It is divided into two categories. The general assembly of the paver/ finisher is addressed first. This is the basic assembly required of all machines to get it “road ready” and prepared to perform basic paving. Secondly, we address the installation of the available options for your paver. These assembly instructions are separate stand alone procedures and apply only to Paver/ Finishers that have been purchased with the optional equipment being addressed.

GENERAL ASSEMBLY As mentioned earlier, some basic assembly is required for all models and should be performed completely before attempting to operate your paver/finisher in any fashion with the exception of placing the machine in an appropriate work area. The guidelines are broken down into the following tasks: •

Before you begin

•

Unloading the machine

•

Installation of the steering guide

•

Installation of the edger-plate assemblies

•

Installation of the automatic feed control sensors

•

Installation of the muffler

After these items are installed, you will need to install any options you may have. These guidelines are provided in a separate area of this section. First, perform the tasks list ed above as described in the following paragraphs.

Before you Begin Before you attempt to perform any equipment assembly you will need to get the machine into a suitable area for the task to be performed. The following instructions are provided as a guide to this end. It is strongly recommended that only personnel experienced with this machine be involved in these procedures. Inexperienced individuals may make errors that could damage property and jeopardize personnel safety.

2-2


ASSEMBLY

Section 2

Selecting a Site for Assembly Before you unload the machine, you may want to take the time to select an appropriate site for the assembly work you will be performing. Some simple suggestions follow that will make this task easier and more trouble free. First, read this section in its entirety. Take the time to think about what you will have to assemble. Consider all of the optional equipment you have ordered and what will be involved in its installation and setup. Next, select a suitable site for the tasks to be performed. Select a well-lit area with some protection form the elements if possible. If that is not practical, do your best to select a dry, level area where sure-footed workers will have adequate light to read and follow instructions, select tools and read instruments. Finally, take the time to gather an adequate set of tools for the job. This will ensure that the task can be completed in a professional manner without needless interruptions.

Unloading the Machine

!

WARNING

Personal Injury/Property Damage Do not allow inexperienced or untrained personnel to move this machine. Only qualified individuals who have been properly trained should be allowed to operate this machine, even for the simple task of relocating or moving the machine. Failure to adhere to this Warning coul d result in property damage, severe physical injury or even death.

!

CAUTION

Equipment Damage Make sure all fluid levels are adequate for operation. Check engine oil levels before attempting to start the engine. If necessary, top fluid off before beginning operation. Failure to adhere to this Caution could result in equipment damage, performance degradation or premature failure of mechanical components.


2-3

Section 2

ASSEMBLY

You will probably have to unload the machine from a tractor-trailer, truck or a f lat-bed railroad car. The easiest and safest way to do this is to drive it off the transport vehicle onto a loading dock that is level with the vehicle bed. To do this, perform Steps 1 through 25. If no loading dock is available, you may use a set of ramp boards. Be sure the ramp boards are of sufficient strength to s upport the weight of the machine. Set the ram p boards at an angle of 12° or less. After the ramp boards are in place, perform Steps 1 through 25 to off load the machine. As a last resort, you could use a crane to unload the vehicle. Before attempting to lift the machine, make sure you have removed any separate parts from the truck bed and removed all equipment that secured the machine in the truck bed , including tie downs, chock blocks and blocks under the frame. A crane with a 20-ton (18T) capacity is required. Position the lifting sling properly so that the load will be centered. After the machine has been removed from the transport and gently placed on the ground, perform Steps 3 through 25. 1. First remove any separate parts from the truck bed. 2. Remove all tie-down equipment, chock blocks and blocks under the frame. 3. Inspect the machine for damage that may have occurred in transit. 4. Inspect the area around the machine for signs of fluids. If there are signs of fluid leaks, clean the area before proceeding and replace any lost fluid before attempting to move the machine. 5. Check fluid levels, such as engine oil, hydraulic oil, etc. 6. Make sure the tires are properly inflated. If necessary add air before attempting to move the vehicle.

!

CAUTION

Possible Equipment Damage If the parts package sitting in the hopper cannot be removed before starting the machine, make sure the CONVEYOR IS OFF. Inadvertent operation of the conveyors may result in damage to packaged material and the conveyors themselves. 7. Mount the machine using the steps and handrail provided at the rear of the machine. 8. If necessary, install seats on the seat posts.

2-4


ASSEMBLY

Section 2

9. Unlock and open the cover (3, Figure 2-1) on the swing console to gain access to the main control panel. Figure 2-1

10. Position the main control panel to a position suitable for the side of the machine you will be seated. 11. Position the Direction/Speed Control Lever (2, Figure 2-1) to the NEUTRAL (centered) position. 12. Place all control switches on the main control panel to the OFF or centered position. 13. Position the THROTTLE Switch (32, Figure 2-2) to the IDLE (center) position. Figure 2-2

14. Position the TRANS Switch (20, Figure 2-2) to the LOW position. 15. Position the MOTOR Switch (21, Figure 2-2) to the LOW position.


2-5

Section 2

ASSEMBLY

16. At the Direction/Speed Control Lever to be used, rotate the hinged lockout plate out of the way, so that the lever is free to move into the reverse range. 17. Pull the Engine Kill Button (19, Figure 2-2) all the way out. 18. Push the STARTER Button (18, Figure 2-2). The engine should start and come up to speed. Note that the engine will not start if the Direction/Speed Control Lever is not in the NEUTRAL position. 19. Wait approximately 3 minutes to allow the engine to warm up. 20. Position the screed to a position above the ground, using the SCREED Control Switch (24, Figure 2-2). Make sure the screed cylinders are retracted sufficiently to engage the locking support brackets (1, Figure 2-3) on the lefthand and right-hand hydraulic screed cylinders. Figure 2-3

21. Make sure the SCREED Control Switch (24, Figure 2-2) is returned to the HOLD (center) position after you have positioned the screed to the desired height. 22. Manually secure the screed in it’s elevated position using the locking support brackets (1, Figure 2-3) on the left-hand and right-hand hydraulic screed cylinders. NOTE: The further the Direction/Speed Control Lever is moved from NEUTRAL the greater the machine velocity will be. 23. Move the Direction/Speed Control Lever (2, Figure 2-1) in the FWD or REV direction as necessary to move the machine in the desired direction. 24. To stop the machine, bring the Direction/Speed Control Lever (2, Figure 2-1) back to the NEUTRAL position. 25. When the machine is positioned in an appropriate area to commence assembly, place the Direction Speed Control Lever (2, Figure 2-1) to the NEUTRAL position and fully depress the Engine Kill Button (19, Figure 2-2) on the main control panel. The parking brake will automatically engage.

2-6


ASSEMBLY

Section 2

Installation of the Steering Guide The following provides a guideline to be followed when installing the steering guide on the Paver/Finisher. 1. Decide which operating position on the deck will be used (right-hand or lefthand). This decision should be based on location of a ground steering reference in relation to the direction of the machine travel when paving. Typical references are road center line, existing mat edge, curb stringline, side of building, etc. 2. Install the steering guide (1, Figure 2-4) through the respective right-hand or left-hand push-plate bracket (2, Figure 2-4). Figure 2-4

3. The chain end is extended for ground-level references. The spring end can be used up against high curbs or sides of a building. 4. The steering guide can be extended to align with the mat edge being placed by the screed. 5. Tighten the bracket set screw to secure in the selected position.


2-7

Section 2

ASSEMBLY

Installation of the Edger-Plate Assemblies Left-hand and right-hand edger-plate assemblies mount on the respective ends of t he screed. The following provides a guideline to be followed when installing these edger-plate assemblies on your screed. NOTE: The left-hand frame contains three holes, while the right-hand frame contains three mounting mandrels. 1. Begin installing the edger-plate frames (4, Figure 2-5) onto their respective ends of the screed by installing the three mounting mandrels (they are shipped loose); two large (3, Figure 2-5) and one small (6, Figure 2-5) in the left-hand outer end of the screed. Figure 2-5

2. Align the three mandrels and the three holes of the screed and edger-guide frames. 3. Insert the mandrels through the holes until the mandrel slots are exposed on the opposite side of the mounting member. R efer to Figure 2-6 for details of the wedge pin attaching and adjusting assemblies. NOTE: Use the slide hammer provided to drive the wedge-keeper pins into the slots securing the edger-plate assemblies in position. 4. Fasten the edger-plate frames (4, Figure 2-5) on the outer end of the screed using the wedge keepers (2, Figure 2-5). NOTE: When installing the edger -plate assemblies for the first time it may be necessary to adjust for proper alignment with the screed.

2-8


ASSEMBLY

Section 2

NOTE: Mounting mandrels have angles slots. The large opening must be up to prevent jamming of the wedge. 5. Adjust the the lower-rear lower-rear and the upper mounting mandrels mandrels (5, Figure Figure 2-6). 2-6). Figure 2-6

NOTE: Special wrenches are provided to turn the lock nut and adjust the nut. 6. Loosen the two lock lock nuts (3, (3, Figure 2-6) and and the two mandrel mandrel nuts nuts (2, Figure Figure 26) while the wedge keepers (1, Figure 2-6) remain loosely installed. 7. Turn the adjusting adjusting nut (4, (4, Figure Figure 2-6) at at each location location and and observe observe the eccentric eccentric action on the edger-guide frame. Turning the lower-rear adjusting nut causes the rear of the edger-guide frame to move up-down. 8. Adjust the the position position of the edger-g edger-guide uide mounting mounting plate plate until until it is perpendi perpendicular cular with the bottom of the screed plate using these adjusting nuts. 9. Set all all three three wedge wedge keepers keepers firmly firmly in the mounting mounting mandrel. mandrel. 10. Tighten the two nuts and lock nuts (2 and 3, Figure 2-6) against the screed frame to maintain the setting you just achieved. 11. Slide the edger-plate (4, Figure 2-7) rearward into the edger-guides (1, Figure 2-7) and secure with the guide hardware (11, Figure 2-7). 12. Assemble the upper and lower-spring-guide lower-spring-guide tubes (6 and 7, Figure 2-7) with two springs inside. The upper tube screen applies pressure on the bottom of the edger-guide as shown.


2- 9

Section 2

ASSEMBLY

13. The lower tube (7, Figure 2-7) should be mounted on the studs on the bottom rail of the edger-plate. 14. Attach the edger-plate edger-plate chains (8, Figure Figure 2-7) to the jack hooks. Figure 2-7

Installation of the Automatic Feed Control Sensors Operation of the left-hand and right-hand auger/conveyor system is controlled either by the paddle sensors or the Ultra 3s (Ultra Sonic Sensors) installed at the outer ends of the respective auger system.

Installation of the Paddle Sensors The following steps represent a guide f or the installation of the paddle sensors. If you are going to use the Ultra 3s, ignore this paragraph. Installation instructions for the Ultra 3s are provided in the next paragraph, beginning on page 2-12. NOTE: If you will be using a OmniScreed 1A or 3/6 Hydraulic Screed extensions, place the paddle sensors in such a manner that they will travel in and out on the extensions to accurately measure the head of the material at the outer extremities of the screed. See the paragraph for installation of these options for instructions on how-to-properly place these sensors.

2-10


ASSEMBLY

Section 2

1. Mount the the paddle paddle sensors sensors (1, Figure Figure 2-8) 2-8) on the main frame frame for basic-wi basic-width dth paving or on the outer ends of the auger guards/tunnels for extended-width paving. Figure 2-8

NOTE: Step 2 below is general in nature and will position the paddle sensors at a typical starting point. Usually, additional adjustment is required for optimum material control. Factors such as paving width, depth and material composition all affect the sensor’s performance. Some experimentation is usually necessary to obtain the best possible position and orientation. 2. The location location of the the paddle paddle sensors sensors with respect respect to the ground, ground, controls controls the head head of the material. Perform the following to set the height of the paddle sensors: NOTE: There must be adequate clearance between the edger-plates and the sensors to allow for unrestricted movement. a. Loosen the thumb thumb screw that secures secures the paddle sensor in in the vertical vertical plane. b. Raise the the sensors sensors in their their mounting mounting brackets so that the bottom bottom edge edge of the the sensor is 102 mm (4-in.) from the surface of the ground. c. Verify that the the sensor sensor paddles paddles hang hang verticall vertically y and are angled angled up up to approximately 15° rearward. d. Make sure sure the paddle paddle sensors swing swing up parallel parallel to the the edger-plate edger-plates. s. e. Tighten the thumb thumb screw securing securing the paddle paddle sensor in place place after all of the the above conditions are met.


2-11

Section 2

ASSEMBLY

!

CAUTION

Equipment Damage. Take care to avoid cable routings which may pinch or strain the wire or plug. Failure to do so may result in d amage to cable or plug resultin g in system failure or degraded performance. 3. Lead the the sensor sensor cables (1, Figure Figure 2-9) 2-9) outside outside of the side arms arms to the cleats (2, (2, Figure 2-9) and then plug into the respectiv e left-hand or right-hand receptacles (3, Figure 2-9) on the rear bulkhead. Figure 2-9

Installation of Ultra 3 s Ultra Sonic Sensors The following provides a guideline for installing the Ultra 3s sensor system on the Paver/ Finisher. 1. Moun Mountt the the Ultr Ultra a 3s controllers (2, Figure 2-10) on the upright blades (3, Figure 2-10) at the left-hand and right-hand upper corners of the tractor. 2. Connect the the plugs from from each controller controller into their their respective respective receptac receptacles les on the rear tractor frame (1, Figure 2-10). 3. Inst Instal alll the the Ultr Ultra a 3s sensors (1, Figure 2-11) on the left-hand and right-hand edger-guides (2, Figure 2-11) keeping the following in mind:

2-12


ASSEMBLY

Section 2

•

Position the sensors forward of the normal head of material and aim near the top of the material pile at a right angle.

•

Sensors should be located approximately 381 mm (15-in.) from the surface when the maximum head of material is present in front of the screed. The maximum desirable head of material occurs when the paving material just covers the auger shaft over its entire length. Figure 2-10

Figure 2-11


2-13

Section 2

ASSEMBLY

Muffler Installation Paver/Finishers are typically shipped without a muffler installed because it is impossible at the time of manufacture to determine the specific requirements of your individual machine which depends primarily on where in the country or world it’s going to be placed in service. Your dealer can assist you in resolving these requirements and selecting the appropriate muffler/ exhaust system that will work properly with your paver/finisher while meeting your specific operational needs.

OPTIONAL INSTALLATION GUIDELINES The purpose of this second portion of the assembly section is to provide guidelines for the installation of the optional features selected for your machine. These guidelines are broken down as follows: •

Installation of the cut-off plate

•

Installation of additional augers (for extended paving width)

•

Installation of 1 foot bolt on screed extension

•

Installation of 18-inch tapered-joint extension

•

Installation of the 8-ft. wedge-lock screed

•

Installation of the Ultra 4 Sonic averaging system and sonic joint matcher

•

Installation of the AGS (7.5) controls

Installation of the Cut-off Plate NOTE: Be sure to remove the wear strips from the bottom of the edgerplates before attempting to install the cut-off plates. The following provides guidelines for the installation of cut-off plates. Cut-off plates are used to reduce the standard 2.44 meter (8-ft.) paving width in 76-mm (3-in.) increments up to 610mm (24-in.) increments. 1. Remove the wear strips from the edger-plates.

2-14


ASSEMBLY

Section 2

2. Install the cut-off plates (1, Figure 2-12) on the bottom of the edger-plates, as shown in Figure 2-12. Figure 2-12

Installation of Additional Augers The following provides guidelines for the installation of additional augers. When paving at a constant extended width, the installation of additional augers and tunnels will improve material distribution to the screed extensions and help to maintain a proper head of material. Read these instructions in their entirety before attempt ing to install any additional auger lengths. The following paragraphs explain some basic concepts that must be understood before you can expect to perform these procedures in an efficient manner.


2-15

Section 2

ASSEMBLY

The exploded view shown in Figure 2-13, which is the left-hand side assembled for 16-ft. paving, typifies the use of all components required to reach various extended widths. Figure 2-13 illustrates the 16-ft. arrangement going together in four stages. Figure 2-13

2-16


ASSEMBLY

Section 2

Figure 2-14 illustrates auger extension components needed for various specific extended widths from 10-feet to 18-feet. These illustrations should be used to identify the exact parts and quantities required for all extended widths. Figure 2-14

NOTE: Arrangement dimensions are assumed to be symmetrical about the center of the main screed. •

For odd dimensions paving widths, always use the configuration shown for the next smaller even dimension arrangement (i.e., for 17-ft. wide paving assemble as shown for 16-ft.).


2-17

Section 2

ASSEMBLY

•

If offset paving is to be performed, determine the 1/2 dimension for each side of the machine and assemble the augers, tunnels and guards according to the appropriate illustration.

•

For 9 ft. through 11-ft. paving, the kickout augers work satisfactorily.

•

10-ft. paving will work as illustrated or could be accomplished by offsetting 2-ft. to one side and assembling that side only, according to the 12-ft. arrangement.

•

11-ft. paving could be accomplished by offsetting 3-ft. and assembling according to the 12-ft. arrangement or it could be accomplished by offsetting 3-ft. and assembling according to the 14-ft. arrangement on either the left or right side.

There are three types of auger tunnels: •

The inner short stepped tunnel (5, Figure 2-13) comes in both left-hand and righthand versions.

•

The middle long tunnel (2, Figure 2-13) which supports the additional auger bearing (8, Figure 2-13) also comes in left-hand and right-hand versions.

•

The outer short tunnel (1, Figure 2-13) can be mounted on either side. Short and long flaps (7 and 10, Figure 2-13) install on the bottom of the respective tunnels.

For paving width of 16-ft. and beyond, forward and upper bracing is required to maintain adequate rigidity in the extended auger/tunnel structure. The forward (3, Figure 2-13) and upper (4, Figure 2-13) braces are detailed in Figure 2-14 for both medium and wide paving widths. Augers consist of cast, 180° auger segments which install staggered, back-to-back with shaft covers shown. There are long auger segments (11, Figure 2-13) with long cast shaft covers (12, Figure 2-13) and there are also short auger segments (13, Figure 2-13) backed by short covers (14, Figure 2-13). Depending on the width to be assembled, inner tubes (15, Figure 213), intermediate shafts (16, Figure 2-13) and outer tubes (17, Figure 2-13) will be required for mounting of the auger segments. If the paving width is to be 14-ft. or more, support bearings (8, Figure 2-13) are also required. Perform the steps outlined below to install an auger extension: NOTE: Auger-extension flights are directional (left-hand and right-hand) and must be assembled on the correct side of the machine to feed material outward. Make sure they are installed properly by comparing the direction of the extension to that of the basic augers.

2-18


ASSEMBLY

Section 2

!

WARNING

Personnel Injury Never use auger-guard extensions without appropriate auger guards. Always install the left-hand and right-hand auger guards (7 and 8, Figure 2-13) as shown for maximum safety. Failure to do so may result in serious personnel injury or even death. 1. Remove the kickout auger segments (1, Figure 2-15) from the end of the basic auger shaft. Figure 2-15

2. Install auger tunnels, (2, Figure 2-16) and bottom flaps (3, Figure 2-16). Refer again to Figure 2-14 for specific components needed to reach various widths. Figure 2-16

3. Assemble auger shafts and tubes (4, Figure 2-17), including support bearings (5, Figure 2-17).


2-19

Section 2

ASSEMBLY

4. Attach auger guards (6, Figure 2-17) to auger tunnels. Figure 2-17

5. Assemble auger segments (7, Figure 2-18) and corresponding shaft covers (8, Figure 2-18) on the shafts. Figure 2-18

6. Install forward and upper braces (9 and 10, Figure 2-19) to maintain rigidity Figure 2-19

2-20


ASSEMBLY

Section 2

Installation of 1-foot Bolt-on Screed Extension The 1-ft. bolt-on screed extension is an add-on for the UltiMat® Screed. The 1-ft. bolt-on extension (1, Figure 2-20) is an ambidextrous extension that bolts on to the end of the primary extension (2, Figure 2-20). This extension features electric heat, an adjustable pre-strike-off plate and an adjustable angle-of-attack for the screed plate. The edger-plate assembly (3, Figure 2-20) then bolts onto the outboard edge of the bolt-on extension. Figure 2-20

The following steps provide a guideline for installation of the 1-foot, bolt-on screed extension. 1. Fully extend the primary extension where the 1-foot bolt-on extension will be mounted. 2. Remove the edger-plate assembly on that side. Four cap screws attach the edger-plate frame to the end of the extension. 3. Lower the screed to the ground. 4. Align the bolt-on extension so that the holes in the extension frames match.


2-21

Section 2

ASSEMBLY

5. Insert one cap screw (1, Figure 2-21), one hardened washer and one lock washer into each of the four mounting holes. Snug the cap screws, but do not tighten yet. Figure 2-21

6. Raise the screed and secure it in position using the supports on the screed lift cylinders. 7. Check the vertical alignment of the bolt-on extension compared to the primary extension screed plate and adjust, as necessary. 8. Rotate the adjustment link (4, Figure 2-20) to match the angle-of-attack on the bolt-on extension with the angle-of-attack on the primary extension. 9. Torque the cap screws (1, Figure 2-21) to 271 N•m (200 lb.-ft.) when satisfied with the alignment achieved in Step 8 above. 10. Locate the harness supplied in the bolt-on extension kit. 11. Connect the heat mat on the bolt-on extension into the power circuit using the harness.

2-22


ASSEMBLY

Section 2

12. Connect this harness to the available clip on the primary extension power harness. 13. Set the height of the bolt-on extension pre-strike off 6 mm (1/4-inch) above the bottom of the screed plate as shown in Figure 2-22. Figure 2-22

14. Bolt the edger-plate to the outboard side of the bolt-on extension, using four cap screws, four hardened washers, four lock washers and four hex nuts. 15. Reinstall the vibrator cover on the back of the primary extension.


2-23

Section 2

ASSEMBLY

Installation of the 18-inch Tapered-Joint Extension The 18-inch (475 mm) bolt-on extension (1, Figure 2-23) is a right-handed or left-handed extension that bolts onto the end of the primary extension. T his extension can create a tapered wedge up to 152 mm (6-in.) tall with no notch, or a tapered wedge up to 127 mm (5-in.) tall with a maximum 25 mm (1-in.) notch. Refer to Figure 2-24. Figure 2-23

Figure 2-24

1. Fully extend the primary extension where the 18-inch, tapered-joint extension will be mounted. 2. Remove the edger-plate assembly on that side. Four cap screws attach the edger-plate frame to the end of the extension. 3. Lower the screed to the ground. 4. Align the 18-inch tapered-joint extension so that the holes in the extension frames match.

2-24


ASSEMBLY

Section 2

5. Insert one cap screw, one hardened washer and one lock washer into each of the five mounting holes (1, Figure 2-25). Figure 2-25

6. Snug the cap screws, do not tighten completely at this time. 7. Raise the screed and secure it in position using the supports on the screed lift cylinders. 8. Check the vertical alignment of the 18-inch tapered-joint extension compared to the primary extension screed plate and adjust as necessary. 9. Torque the cap screws to 271 N•m (200 lb.-ft.) when satisfied with the alignment achieved in Step 8 above. 10. Bolt the edger-plate to the outboard side of the 18-inch, tapered-joint extension, using four cap screws, four hardened washers, four lock washers and four hex nuts. 11. Reinstall the vibrator cover on the back of the primary screed extension.


2-25

Section 2

ASSEMBLY

Installation of the 8-foot Wedge-lock Screed The following provides a guideline for installation of t he 8-ft. wedge-lock screed on the PF-161 paver/finisher. Read these guidelines in their entirety before attempting to install the wedgelock screed. 1. Position the paver/finisher with the screed in a manner that will facilitate the installation of the 8-ft. wedge-lock screed. 2. Connect the tow-point cylinder (7, Figure 2-26) to the screed side arm (8, Figure 2-26) as follows: a. Insert the clevis pin to connect the tow-point cylinder and screed side arm, position washers. b. Insert the cotter pin at the bottom of the cylinder. Figure 2-26

3. Connect the screed lift cylinders (5, Figure 2-27) at the lower end of the cylinder as follows: a. Position cylinder (5, Figure 2-27) over the mounting block (8, Figure 2-27). b. Drive the clevis pin (7, Figure 2-27) through the cylinder bracket and the mounting block (8, Figure 2-27).

2-26


ASSEMBLY

Section 2

c. Secure by inserting the cotter pin (6, Figure 2-27) at the bottom of the cylinder. Figure 2-27

4. Connect the side arms to the tow points as follows: a. Insert the clevis pin (3, Figure 2-29) into the side-arm cylinder (4, Figure 2-29).

Figure 2-28

b. Attach to side arm using nut, bolt and front guide roller (2, Figure 2-28).


2-27

Section 2

ASSEMBLY

5. Connect the fuel cap hose (1, Figure 2-29) to the rear bulkhead of the tractor which supplies fuel to the screed burners Figure 2-29

6. Connect all hydraulic connections. 7. Connect all electrical connections.

Installation of Ultrasonic 4 Sonic Averaging System/Sonic Joint Matcher This system is also known as the Automatic Level Control or simply the Joint Matcher. The system controls the elevation of the mat being placed on one side (single) or both sides (dual) of the paver/finisher with respect to a reference surface such as an adjacent mat or curb. It controls the screed by automatically raising and lowering the tow point of the screed side arm or, in the case of dual operation, both side arms. The following steps provide a guideline for the installation of the Automatic Level Control (Joint Matcher) system. During the performance of this procedure, keep in mind that the sensor may be installed on either side depending on the location of the reference surface and the anticipated direction of travel.

2-28


ASSEMBLY

Section 2

Perform the steps below to install the system: 1. Install the sensor as shown using the screed end tube (2, Figure 2-30), mounting hardware (3, Figure 2-30) and jack (4, Figure 2-30) to reach the reference surface (just outside the paver’s edger-plate). Figure 2-30

2. Jog the cylinders up or down until the holes in the side arm and side arm guide line up (5, Figure 2-32). Figure 2-31


2-29

Section 2

ASSEMBLY

NOTICE The step below applies only to single-sensor systems. And only the opposite side of the machine from the sensor is affected. 3. When using a single sensor, lock the side arm located on the opposite side of the machine in the centered position, using the hand valve (6, Figure 2-31). Turn the valve off by moving it to the closed position. 4. Set the Mode Switch (7, Figure 2-30) on the sensor to the MONITOR position. 5. Install the sensor on the jack and plug the cord into the receptacle (7, Figure 231). 6. Jack the sensor down until the shoe rests on the reference surface in a trailing direction. 7. With the paver ignition turned ON, adjust the sensor up or down while watching the lights (9, Figure 2-30) until they both become extinguished. The sensor is now nulled with the cylinder. NOTE: Do not lock either side-arm cylinder after centering when using dual controls. 8. If dual sensors are to be installed, repeat Steps 1 through 8 above on the opposite side of the machine.

!

CAUTION

Possible Equipment Damage Before moving the paver around on the job, raise the sensor and secure it for adequate ground clearance. Failure to do so may result in damage to the sensor. 9. Set the Mode Switch (7, Figure 2-30) on the sensor to the AUTO position. The system is now ready for paving.

2-30


ASSEMBLY

Section 2

Installation of the Ags (7.5) Controllers The AGS 7.5 Grade/Slope controllers (2, Figure 2-32) are multipurpose control units that function as either independent grade or independent slope controllers. Perform the following to install these controllers Figure 2-32

1. Position the controller on the top of the control station (1, Figure 2-32) and secure in place using the latches on each side of the control station (3, Figure 2-32). 2. Plug one end of the cable into the control station (4, Figure 2-32) and the other end into the receptacle of the sensor.


2-31

Section 2

2-32

ASSEMBLY


SECTION 3 - OPERATING CONTROLS AND INSTRUMENTS


3-1

Section 3


OPERATING CONTROLS AND INSTRUMENTS DIRECTION-SPEED CONTROL LEVERS The Direction-Speed Control Consoles have a Rev erse Lockout (1, Figure 3-1), and a hinged face plate which is used to prevent the Direction-Speed Control Levers from going in reverse. The Direction-Speed Control Levers (2, Figure 3-1) are mechanical actuators which c ontrol the direction of the machine travel FORWARD-STOP-REVERSE and vary the speed within the limits of the 2-speed traction drive motor and single or 2-speed transmission (dependant on model). An instruction plate indicating these positions is attached to each console. The Direction-Speed Control Levers must be in NEUTRAL to start the engine. Figure 3-1

Steering Units The steering units (3, Figure 3-1) are both active full time.

3-2



Section 3

MAIN CONTROL PANEL The majority of vehicle controls and indicators are located on this common, center-mounted swing console panel with position lock. Refer to Figure 3-2 and Figure 3-4 for various views of this panel followed by a brief explanation of each control and indicator located on the panel itself. The main control panel itself is located between the two driver/operator control stations and is locked in place by a cotter pin so that the control panel is positioned at one of the control stations on one side or the other of the vehicle. This allows for easy setup between the two seats. This panel provides both control stations with electrical switch control of the following:

Main Power

Starter

Throttle

Horn

Shifting of Traction-Drive Motors

Right and Left-Side Feed System Function

Screed Lift

Auger Lift

Folding Hopper

Flowgates

Screed Vibrator Function

Parking Brake

Traction Lock System

Pivot Steering

Optional Truck Hitch

Optional Front-Wheel Power Assist.

The dual control stations (right and left-side) are each equipped with an operator’s seat, steering wheel and direction/speed control console.

Engine Tachometer/Hour Meter The engine Tachometer/Hour Meter (4, Figure 3-2) registers the engine RPM and the total number of hours the engine has operated. It does not continue to accumulate time when the main power is ON and the engine is not running.

Maintenance Indicator The Maintenance Indicator (5, Figure 3-2) illuminates when a maintenance task needs to be performed. This is a reminder only provided for your convenience. DO NOT depend on this indicator to inform you of maintenance requirements. It is your responsibility to perform scheduled maintenance at the recommended intervals. Refer to Section 5, MAINTENANCE INSTRUCTIONS.

Wait to Start Indicator The Wait-To-Start Indicator (6, Figure 3-2) will extinguish when the glow plugs in the diesel engine have completed their pre-heating cycle and the engine is ready to start.


3-3

Section 3


Water in Fuel Indicator The Water In Fuel Indicator (7, Figure 3-2) illuminates when the pres ence of water is detected in the fuel system. Figure 3-2

3-4

4.

Tachometer/Hour Gauge

11.

Oil Pressure Gauge

5.

Maintenance Indicator

12.

Empty Tunnel Indicator

6.

Wait To Start Indicator

13.

Hydraulic Filter Indicator

7.

Water In Fuel Indicator

14.

Water Temperature Gauge

8.

Stop ENG Indicator

15.

Battery Gauge

9.

Check ENG Indicator

16.

Oil Temperature Gauge

10.

Brake Engaged Indicator



Section 3

Stop Engine Indicator

!

CAUTION

EQUIPMENT DAMAGE. SHUT DOWN THE ENGINE IMMEDIATELY IF THE STOP ENG INDICATOR IS ILLUMINATED. FAILURE TO DO SO MAY RESULT IN ENGINE FAILURE RESULTING IN LOSS OF USE AND MAJOR REPAIR COSTS. The STOP ENG Indicator (8, Figure 3-2) illuminates when a major malfunction has been detected regarding the engine. If this Indicator illuminates, SHUT DOWN the ENGINE IMMEDIATELY.

Check Engine Indicator The Check ENG Indicator (9, Figure 3-2) illuminates whenever a possible problem is detected regarding the engine. You do not need to shut down the engine immediately, but you should give the matter you attention as soon as possible.

Brake Engaged Indicator The Brake Engaged Indicator (10, Figure 3-2) illuminates when the park ing brake is engaged, the Main Switch is in the ON position and there is power to the system. The Parking Brake Light will be extinguished when the Parking Brake is disengaged or there is no electric power present.

Oil Pressure Gauge The gauge (11, Figure 3-2) displays the engine oil pressure. The pressure of warmed engine oil should remain above 30 PSI at 2200 revolutions per minute (RPM).

Empty Tunnel Indicator The Empty Tunnel Indicator is functional only if the machine is equipped with an optional Material Level Indicator Kit. The Empty Tunnel Indicator (12, Figure 3-2) illuminates when either of the material indicator sensors mounted on the bott om of the flow gates are no longer contacting the paving material.


3-5

Section 3


Hydraulic Filter Light

!

CAUTION

Possible equipment damage. When the Hydraulic Filter Indicator remains illuminated for extended periods of time (1 hour or more), replace the hydraulic oil filter. Failure to do so may cause premature damage to the hydraulic system or degraded system performance. The Hydraulic Filter Indicator (13, Figure 3-2) rem ains illuminated continuously when it is time to change the hydraulic oil filter. IMPORTANT: The Hydraulic Filter Light will always illuminate at start-up and remain illuminated until the hydraulic fluid heats to the normal operating temperature. Normally, this takes about ten minutes. If the light remains illuminated throughout the day, the filter is restricting the flow and should be replaced as soon as possible.

Water Temperature Gauge The Water Temperature Gauge (14, Figure 3-2) displays the engine water temperature. The temperature of warmed engine coolant shou ld remain below 230° F (110° C) at all times under normal operating conditions.

Battery Gauge The Battery Gauge (15, Figure 3-2) displays the elec trical system voltage. The reading should remain above 10.5 Volts when the engine is operating.

Oil Temperature Gauge The Oil Temperature Gauge (16, Figure 3-2) displays the hydraulic tank oil temperature. The temperature of warmed hydraulic f luid should remain below 230° F (110° C) a t all times under normal operating conditions.

Front Wheel Assist Switch NOTE: These hydrostatic drive units will operate only when the drive motor is in the LOW position and the Direction-Speed Control Lever is in the FORWARD position. They are non-operative in all other traction modes, including NEUTRAL and REVERSE, even though this switch may be in the ON position. The Front Wheel Assist Switch (17, Figu re 3-3) is a two-position switch (ON/OFF) t hat is used to operate the Front Wheel Power Assist units located in the rear bogie wheels beneath the hopper.

3-6



Section 3

Starter Button The Starter Button (18, Figure 3-3) is used to apply power to the starter, thereby starting the engine. Figure 3-3

17.

Front Wheel Assist Switch

23.

L.H. Flowgate Switch

18.

Starter

24.

Screed Control Switch

19.

Engine Kill Button

25.

Auger Control Switch

20.

Transmission Shift

26.

Hopper Control Switch

21.

Motor Shift

27.

Horn

22.

R.H. Flowgate Switch

Engine Kill Button The Engine Kill Button (19, Figure 3-3) is the master switch for all circuits on the machine. This switch must be closed (pulled out) to operate any of the electric ally controlled functions. It may be “hit” (pushed in) to kill all functions. This switch should be opened (pushed in) when the machine is parked or unattended.

Transmission Shift Switch The Transmission Shift Switch (20, Figure 3-3) is used to shift the 2-speed transmission units in each final drive between HIGH and LOW. This switch is spring captured in detent positions to remain in the selected position and resist accidental bumping. The switch must be pulled out to move between the LOW and HIGH positions.


3-7

Section 3


Motor Shift Switch NOTE: Shifting “on-the-go” allows for changing from 1) Low Pave to 2) High Pave. It also allows for ch anging from 3) Low Travel to 4) Hig h Travel without requiring a stop. The Motor Shift Switch (21, Figure 3-3) is used to shift the 2-speed traction-drive motors in each final drive between HIGH and LOW. Shifting the traction-drive motor while the machine is moving is provided by changing the displacement of the motors.

RH Flowgate Control Switch The RH Flowgate Control Switch (22, Figure 3-3) is an OPTION. Not all machines are equipped with this switch. It is used to electrically adjust the right-hand opening in the respective conveyor tunnel to increase or decrease the volume of paving material being delivered to the augers.

LH Flowgate Control Switch The LH Flowgate Control Switch (23, Figure 3-3) is an OPTION. Not all machines are equipped with this switch. It is used to electrically adjus t the left-hand opening in the respective conveyor tunnel to increase or decrease the volume of paving material being delivered to the augers.

Screed Control Switch This Screed Control Switch (24, Figure 3-3) controls the vertical position of the screed. Push the switch to the UP position to raise the screed for transport. The spring-centered switch will return to the HOLD position when released indicating the screed is retained by the hydraulics in whatever position it stops. Push the switch to the DOWN position to allow the screed to lower. Leave the switch in the HOLD position to allow the screed to freely float on the paving material, unrestricted by the hydraulics.

Auger Control Switch NOTE: Auger Override switches located on the Screed Control Boxes take priority on the Control Console Switches in all positions. The Auger Control Switch (25, Figure 3-3) controls the vertical position of the augers varying grade clearance from 114 mm (4 1/2-inches) to 260 mm (10 1/4-inches). Push the Auger Control Switch to the UP position to raise augers and to the DOWN position to lower them. The spring-centered HOLD position indicates the auger is retained by hydraulics in whatever position it stops. In the detent AUTO position, the eruptive auger/conveyor will operate according to signals originating from the Feed Control Sensors and only when the Direction-Speed Lever is in the FORWARD position.

3-8



Section 3

Hopper Control Switch The Hopper Control Switch (26, Figure 3-3) controls the hopper wings. Push it to the Up position to fold the wings in and feed paving materials into the conveyors. Push it to the DOWN position to fold the wings out for loading of the hopper. The spring-centered position indic ates that the hopper wings are retained by the hydraulics in whatever position they stop.

Horn Button The Horn Button (27, Figure 3-3) is used to sound the horn.

RH and LH Conveyor Switches The RH (right hand) and LH (left hand) C onveyor Switches (28, Figure 3-4) act ivate the Auger/ Conveyor Systems on the indicated side of the machine. In the OFF position, the respective auger/conveyor will not operate. In the MANUAL position, the respective auger/conveyor will operate full time at the maximum speed which has been set on the Auger Speed Dial located on the respective Screed Control Box until switched to OFF or AUTO. In the AUTO position the conveyors are cycled on and off automatically via commands from either the ultrasonic sensor or paddle sensors that are part of the Automatic Feed Control system described in Section 1 of this manual. Figure 3-4

33.

Positive Traction Switch

28.

Left-Hand and Right-Hand Conveyor Switches

29.

Parking Brake Switch

34.

Pivot Steer Switch

30.

Screed Vibrator Switch

35.

Truck Hitch Button

31.

Governor Switch

36.

Ventilation Control Switch

32.

Throttle Switch


3-9

Section 3


Parking Brake Switch The Parking Brake Switch (29, Figure 3-4) activates the parking brake when switched to the ON position. The parking brake is always automatically engaged if the machine has a total electrical failure or the Main Power/Engine Kill Switch is “hit”. The parking brake will also automatically engage if there is a sudden drop in general purpose hydraulic pressure. These emergency conditions override all other settings and engage the parking brake regardless of the switch position.

Screed Vibrator Switch The Screed Vibrator Switch (30, Figure 3-4) activates the operation of the screed vibrators in three positions: AUTO, OFF and MANU AL. In the OFF position, the vibrators will not operate. In the MAN position, the vibrators will operate full time until turned OFF or AUTO. I n the AUTO position, the vibrators will operate only when the Direction-Speed Lever (2, Figure 3-1) is moved FORWARD.

Governor Switch The Governor Switch (31, Figure 3-4) controls the maximum engine RPM at f ull throttle. When the control is set to PAVE, the maximum engine RPM is limited to 1800 RPM. When the switch is set to TRAVEL, the maximum engine RPM is increased to 2200 RPM.

Throttle Switch The Throttle Switch (32, Figure 3-4) is a three-position selector for engine throttle speed. The engine will IDLE in the center position at 1000 RPM. When the switch is moved to the FULL position, the engine runs at 2200 RPM. When the switch is moved to the AUTO position, the engine will idle when the Direction-Speed Levers (2, Figure 3-1) are in the NEUTRAL position and the governed RPM will increase automat ically when the levers are moved FORWAR D and REVERSE.

Positive Traction Switch NOTE: Positive traction is intended for limited use. It should only be turned ON when paving on loose bases or slippery surfaces. It should be turned OFF in tight steering situations (i.e., when paving cul-de-sacs or pivot steering). The Positive Traction Switch (33, Figure 3-4) is a two-position switch (ON/OFF) used to turn the positive traction features on or off and prevent loss of traction effort when paving by producing limited slip between the Positive traction drive units.

3-10



Section 3

Pivot Steer Switch The Pivot Steer Switch (34, Figure 3-4) is used to produce tighter turns than can be accomplished by normal steering. When the switch is pushed LEFT or RIGHT, the respective traction pump is stroked to neutral produc ing hydrostatic braking to the inside drive w heel. The opposite drive wheel continues to turn, causing the front end to skid in the chosen direction. While in the pivot steer mode, the inside tire is not locked in position and may rotate a little as the machine turns. This is a normal operating condition.

Truck Hitch In/Out Button The Truck Hitch In/Out Button (35, Figure 3-4) is an OPTION. Not all machines are equipped with this switch. Push this button to the IN position to retract the Truck Hitch. Push this button to the OUT position to open the Truck Hitch. The spring-centered position indicates that the hitch is retained by the hydraulics in whatever position it stops.

Ventilation Control Switch The ventilation control switch (36, Figure 3-4) located on the Operator’s Swing Console, controls the operation of the SmokEater ® Ventilation Control System. Push the switch to the closed position to turn the system fan on. In this position the fan will remain on until the switch is in the center, OFF position or in AUTO. Push the switch down to put it in t he AUTO position. In the AUTO position the fan will activate whenever the Direction-Speed Lever is not in NEUTRAL.

Brake Release Hand Valve The brake release hand valve (38, Figure 3-5) is located beneath the deck and is used to obtain freewheeling of the machine by applying hydraulic pressure to the brake packs within the final drive planetaries. Brakes can only be manually released by applying at least 400 PSI hydraulic pressure using the Hand Pump (37, Figure 3-5) Also see page for Towing instructions.

!

WARNING

Personal Injury Hazard. Do not close the brake release valve except to release the brakes for emergency towing. The machine can roll when the secondary/parking brakes are released. Failure to adhere to this admonishment may result in property damage, serious injury or even death.


3-11

Section 3


Brake Release Hand Pump The brake release hand pump (37, Figure 3-5) is used to manually unlock the brake packs within the final torque hubs by applying at least 400 PSI hydraulic pressure. 25 to 30 strokes are normally required to reach 400 PSI. Figure 3-5

Material Indicator (Option) The material indicator sensors are an option. Not all machines are equipped with the material indicator sensors and lights. The material indicator syste m consist of sensors (39, Figure 3-6) which are installed on the bottom of each of the flow gates. These sensors are connected to a flashing light (Empty Tunnel Indicator, Item to inform the operator when material flow becomes inadequate. They operate similar t o the feed control paddles installed near the ends of the augers to control the material feed. The sensors do not directly control the ON-OFF function of the feed system. That judgement is left to the operator. Figure 3-6

3-12



Section 3

Flow Gate Position Indicators The Flow Gate Position Indicators (40, Figure 3-7) provide the operator with a means of determining the position of the flow gates (39, Figure 3-6) from the operators seat. This is useful as the operator adjusts the flow gates from the main console. Figure 3-7

Rear Control Stations The paver/finisher is equipped with two rear control panels (left and right side) used to help control the grade and slope of the screed during paving. Refer to Figure 3-8 for a view of this control station. Note that if your vehicle is equipped with the optional Blaw-Kontrol II, the control panel arrangement will resemble that shown in Figure 3-9, rather than that shown in Figure 3-8. The controls described in this paragraph, however, are applicable to both configurations. Figure 3-8


41

Jog Toggle Switch

42

Up/Down Indicators

43

3-Position Function Toggle Switch 3-13

Section 3


Jog Toggle Switch The Jog Toggle Switch (41, Figure 3-8) is operational only when the 3-position function toggle switch (43, Figure 3-8) is in the MANUAL position. When operational this switch is connected directly to the respective (right-hand side or left-hand side) control valve.

Up/Down Indicators The UP/DOWN Indicators (42, Figure 3-8) provide an indication of the output signal of the respective grade or slope controllers.

3-Position Function Toggle Switch The 3-position function toggle switch (43, Figure 3-8) selects the type of operation. This selection is either MANUAL, MONITOR or AUTOMATIC. When set to the MANUAL position, the jog toggle switch (41, Figure 3-8) is connected directly to either the right-hand or left-hand (respectively) cont rol valve. The UP and DOWN Indicato rs (42, Figure 3-8) do not flash; they simply indicate the output signal of t he grade sensor or slope controller (Figure 3-9). When set to the MONITOR position, the control valve is not connected to the jog switch and the UP and DOWN Indicator lights (42, Figure 3-8) provide an indication of the output signal of the respective grade or slope controllers (Figure 3-9). When set to the AUTOMATIC position, the solenoid valve is connected directly to the Grade/ Slope controller (Figure 3-9). In this instance, the UP and DOWN Indicators (42, Figure 3-8) not only provide an indication of the output signal of the Grade/Slope controllers, but also indicate the current tow point cylinder action.

3-14



Section 3

Slope/Grade Controller Two optional panels (left and right side) are provided to accurately set slope and grade of the mat. Refer to Figure 3-9 for a view of the slope/grade controller and a list of each control contained on that panel. Note that the slope/grade control panel mounts directly above a standard rear control station (Figure 3-8) also pictured below for clarity. Keep in m ind that the switch/indicator descriptions provided for the control station (Figure 3-8) are applicable with or without the installation of the slope/grade controller. Figure 3-9

44.

Mode Switch

45.

Warning Indicator

46.

LCD

47.

Up/Down Knob

48.

Selector Switch

Mode Switch The Mode Switch (44, Figure 3-9) selects the type of operation, SLOPE LEFT, GRADE or SLOPE RIGHT. The center position of this switch selects GRADE, while the left or right position selects the respective slope function.


3-15

Section 3


Warning Indicator The Mode Switch (44, Figure 3-9) selects the type of operation, SLOPE LEFT, GRADE or SLOPE RIGHT. The center position of this switch selects GRADE, while the left or right position selects the respective slope function.

Warning Indicator The Warning Indicator (45, Figure 3-9) illuminates when the automatic diagnostics have detected a malfunction. At the same time an error code will appear in the LCD (46, Figure 39) that can be used to aid in fault isolation. These error codes are addressed in Section 6, TROUBLESHOOTING.

LCD The Liquid Crystal Display (LCD) (46, Figure 3-9) provides the operator with a wide range of operational information.

Up/Down Knob The UP/DOWN Knob (47, Figure 3-9) is used to control mat depth on the grade side of the machine and maintain/change the slope as required on the opposite side of the machine.

Selector Switch The Selector Switch (48, Figure 3-9) directs output from the potentiometer to maintain or alter either the grade, the slope or the LCD (46, Figure 3-9) depending on the mode.

Screed Control Panels Screed control panels are mounted at each rear corner of the paver/finisher. There is a lefthand (LH) and right-hand (RH) control panel. These panels enable the operator to control the screed from the rear of the machine. Refer to Figure 3-10 and Figure 3-11 for pictures and explanations of each control panel. Even though these panels are almost identical mirror images of one another, separate Figures have been provided for clarity.

3-16



Section 3

LH Control Panel Refer to Figure 3-10 for a view of the LH control panel and a brief explanation of the panel controls. This control panel enables the operator to control the screed from a convenient location. Figure 3-10

49.

Extension Slope Toggle Switch

54.

Extension Fuel Pump Power Switch

50.

LH and RH Flowgate Control Toggle Switches

55.

Main Fuel Pump Power Switch

51.

Auger Override Toggle Switch

56.

Main Igniter Power Switch

52.

Auger Extension Switch

57.

Auger Speed Control Knob

53.

Extension Heater Ignition Switch

58.

Screed Extension In/Out Toggle Switch

Extension Slope Toggle Switch The Extension Slope Toggle Switch (49, Figure 3-10) is used to establish the slope of the respective (LH and RH) primary extendible section in relation to the main screed.Pushing to the down arrow position causes the outer end of the primary extendible section to lower, while pushing the switch to the up arrow position will cause it to raise.

LH and RH Flow Gate Control Toggle Switches These switches (50, Figure 3-10) operate the adjustable flow gates that meter material delivery to the augers on the respective LH and RH side of the machine. Moving a switch upward raises the respective gate, while moving the switch downward lowers the gate. While the switch is in the center position, the gate will remain stationary. These Flow Gate Control Toggle Switches are unique to the LH Control Panel and are one of the few switches that are not shared between the two panels.


3-17

Section 3


Auger Override Toggle Switch The Auger Override Toggle Switch (51, Figure 3-10) allows the operator to take local control of the auger. When this switch is in the OFF position, control of the auger/conveyor system remains with the feed control sensors. When the switch is moved to the left or right position, local control of the respective auger/conveyor system is transferred to this control panel.

Auger Extension Switch The Auger Extension Switch (52, Figure 3-10) enables the operator to locally move the auger extensions. Pressing this switch will cause the auger extensions to operate under local control.

Extension Heater Igniter Switch The Extension Heater Ignition Switch (53, Figure 3-10) when used in conjunction with the Extension Fuel Pump Switch (54, Figure 3-10) allows the operator to operate the heater for the screed extensions.

Extension Fuel Pump Switch The Extension Fuel Pump Switch (54, Figure 3-10) when used in conjunction with the Extension Heater Igniter Switch (53, Figure 3-10) allows the operator to operate the heater for the screed extensions.

Main Fuel Pump Power Switch The Main Fuel Pump Power Switch (55, Figure 3-10) operates the fuel pump for the main screed heater. Note that this switch must be in the ON position in order for the Extension Fuel Pump Switch (54, Figure 3-10) to become operative.

Main Igniter Power Switch The Main Igniter Power Switch (56, Figure 3-10) allows ignition of the main screed heaters. Note that this switch must be in the ON position in order for the Extension Heater Igniter Switc h (53, Figure 3-10) to become operative.

Auger Speed Control Knob The Auger Speed Control Knob (57, Figure 3-10) becomes active when the Auger Override Toggle Switch (51, Figure 3-10) has been engaged. Otherwise, this control is inoperative. When operating, this knob provides a variable range auger/conveyor system speed control. Clockwise rotation increases the speed of the auger/conveyor system, while counterclockwise rotation slows the speed of the system.

3-18



Section 3

Screed Extension In/Out Toggle Switch The Screed Extension IN/OUT Toggle Switch (58, Figure 3-10) allows the operator to change the position of the screed extensions. Pressing the toggle switch to the IN position will retract the screed extensions. Pressing the toggle switch to the OUT position will extend the screed extensions. When the switch is in it’s center position the screed extensions wi ll remain in their established positions.

RH Control Panel Refer to Figure 3-11 for a view of the RH control panel and a brief explanation of the panel controls. This control panel enables the operator to control the screed from a convenient location. Figure 3-11

59.

Extension Fuel Pump Switch

64.

Extension Slope Toggle Switch

60.

Extension Heater Igniter Switch

65.

Screed Extension In/Out Toggle Switch

61.

Auger Override Toggle Switch

66.

Auger Speed Control Knob

62.

Auger Extension Switch

67.

Main Igniter Power Switch

63.

Fuel Pump Switch

68.

Main Fuel Pump Power Switch

Extension Fuel Pump Switch The Extension Fuel Pump Switch (59, Figure 3-11) when used in conjunction with the Extension Heater Igniter Switch (60, Figure 3-11) allows the operator to operate the heater for the screed extensions.


3-19

Section 3


Extension Heater Igniter Switch The Extension Heater Igniter Switch (60, Figure 3-11) when used in conjunction with the Extension Fuel Pump Switch (59, Figure 3-11) allows the operator to operate the heater for the screed extensions.

Auger Override Toggle Switch The Auger Override Toggle Switch (61, Figure 3-11) allows the operator to take local control of the auger. When this switch is in the OFF position, control of the auger/conveyor system remains with the feed control sensors. When the switch is moved to the left or right position, local control of the respective auger/conveyor system is transferred to this control panel.

Auger Extension Switch The Auger Extension Switch (62, Figure 3-11) enables the operator to locally move the auger extensions. Pressing this switch will cause the auger extensions to operate under local control.

Fuel Pump Switch The Fuel Pump Switch (63, Figure 3-11) operates the fuel pump that provides fuel to all heaters (both main and extensions). This switch must be in the ON position to energize the fuel pump for the screed heaters to operat e. The Fuel Pump Switch is unique to the RH Control Panel and is one of the few that are not shared between the two panels.

Extension Slope Toggle Switch The Extension Slope Toggle Switch (64. Figure 3-11) is used to establish the slope of the respective (LH and RH) primary extendible section in relation to the main screed. Pushing to the down arrow position causes the outer end of the primary extendible section to lower, while pushing the switch to the up arrow position will cause it to raise.

Screed Extension In/Out Toggle Switch The Screed Extension IN/OUT Toggle Switch (65, Figure 3-11) allows t he operator to change the position of the screed extensions. Pressing the toggle switch to the IN position will retract the screed extensions. Pressing the toggle switch to the OUT position will extend the screed extensions. When the switch is in it’s center position the screed extensi ons will remain in their established positions.

Auger Speed Control Knob This Auger Speed Control Knob (66, Figure 3-11) becomes active when the Auger Override Toggle Switch (61, Figure 3-11) has been engaged. Otherwise, this control is inoperative. When operating this knob provides a variable range auger/conveyor system speed control. Clockwise rotation increases speed of the auger/conveyor system, while counterclockwise rotation slows the speed of the system.

3-20



Section 3

Main Igniter Power Switch The Main Igniter Power Switch (67, Figure 3-11) allows ignition of the main screed heaters. Note that this switch must be is in the ON position in order for the Extension Heater Igniter Switch (60, Figure 3-11) to become operative.

Main Fuel Pump Power Switch The Main Fuel Pump Power Switch (68, Figure 3-11) operates the fuel pump for the main screed heater. Note that this switch must be in the ON position in order for the Extension Fuel Pump Switch (59, Figure 3-11) to become operative.


3-21

Section 3

3-22

OPERATING CONTROLS AND INSTRU-


SECTION 4 - OPERATING INSTRUCTIONS


4-1

Section 4


OPERATING INSTRUCTIONS GENERAL This section contains general operating guidelines for the PF-161 Paver/Finisher. These guidelines are presented in a high-level topically general manner since it is impossible to predict your exact operating parameters. This section contains the following topics: •

Pre-start checks and verifications

•

Starting the machine

•

Operating the machine

•

Moving the machine between worksites

•

Loading the machine under its own power for transport

•

Securing the machine to the transporter

•

Towing the machine

Pre-Start Checks and Verifications Before starting the PF-161 Paver/Finisher, the machine should be inspected to verify that each is in good operating condition using the following checklist as a guide: 1. Check fuel level in the fuel tank 2. Engine lubricating oil at the proper level 3. Engine coolant in the coolant recovery bottle at the proper level 4. Hydraulic reservoir fluid at the proper level 5. Machine lubricated in accordance with the instructions in this manual 6. No visible signs of equipment damage 7. Check parking brake on flat open ground. Low speed range (Low Motor Shift Switch position) should not overpower brake. If parking brake can be overpowered, brake packs inside of final drive planetaries must be repaired. Parking brake is not adjustable. 8. Front-wheel-assist relief pressure should be set according to operating surface. Also check the following items periodically or where applicable, refer to the Section 5, MAINTENANCE INSTRUCTIONS of this manual. 9. Planetary fluid is present at the proper level 10. Engine fuel and air filters. Engine properly tuned and operating smoothly. Tension in the Fan Belt has been properly adjusted so that the Fan Belt is tight. 11. Sufficient hydraulic pressure

4-2



Section 4

12. Conveyors adjusted properly and wear checked. Refer to Section 5, MAINTENANCE INSTRUCTIONS of this manual. 13. Auger/Conveyor drive chains adjusted properly and auger wear checked. Refer to the Section 5, MAINTENANCE INSTRUCTIONS of this manual. 14. Drive tires properly inflated (35 ±5 psi). 15. Inspect screed for excessive wear. 16. Inspect screed heaters and gas lines for serviceability. 17. Check for excessive play in crown jack and their mountings. 18. Check for smooth operation of the mat thickness adjusting screws.

Starting the Machine The following are general guidelines to be adhered to when starting up the machine. These guidelines are divided into several categories. Below is a list of these general startup categories followed by the guidelines for each. •

Suggestions to make cleanup easier

•

Positioning the machine and its controls

•

Initial screed elevation

•

Initial screed angle-of-attack

•

Lighting the screed heater

•

Positioning of material truck and starting to pave

Suggestions to Make Cleanup Easier

!

WARNING

Fire Hazard Never use the wash-down spray while the screed heaters are operating. The wash down spay is fuel and could ignite. Failure to adhere to this warning may cause serious injury or even death.


4-3

Section 4


Just prior to starting to lay bituminous base materials, apply Blaw-Kote ® Lubricant Shield, or use the machine’s wash down hose to wet all surfaces with fuel oil which will come in contact with paving material to prevent paving material from adhering to the mechanical components of the paver/finisher. These surfaces typically are: •

Push rollers

•

Hopper

•

Conveyors

•

Augers

•

Screed face and bottom

•

Screed extensions

•

Edger plates

Positioning the Machine and its Controls

Keep the following criteria in mind when initially positioning the machine for a job: •

Position the machine on the joint or point from which the paving is to start.

•

Screed extensions should be appropriately adjusted if the job requires their use.

•

Feed control sensors should be installed.

•

Choose the operator’s position (left-hand or right-hand) which provides maximum visibility in relation to a steering reference and/or obstacles on the job.

•

Position the steering guide in relation to the steering reference (if it is to be used).

•

If the Automatic Level Control (Joint Matcher) option attachment is to be used, make certain that it is set up and operating properly.

•

Initially set flow gates as recommended. Final precise adjustment is made after paving has started and material demand on each side of the screed versus supply is observed.

Initial Screed Elevation

When starting to lay a bituminous mat, it is essential that the bottom of the screed be elevated from the grade a distance equal to the desired mat depth plus enough extra height to allow for mat compaction by rolling. This is normally accomplished by placing wood starting blocks of the required thickness under each end of the screed. Example: If a finished mat of 51 mm (2in.) is to be laid, starting blocks 65 mm (2.5 in.) thick would provide a suitable starting height. Note that starting to pave from the end of a previousl y laid mat, starting blocks with a thickness only to the amount of compaction are all that is requir ed (14 mm(0.5-in.)) with reference to the foregoing example. When initially setting up the screed elevation, keep the following guidelines in mind: •

4-4

Starting blocks should be as long, or longer, than the dimension of the screed plate (front to rear).



Section 4

•

Starting blocks should be placed longitudinally with the paver’s direction of travel, one under and near each end of the screed.

•

Starting block placement will provide the screed plate with a full bearing parallel surface under each end that is essentially parallel with the grade and on which the screed can be nulled out.

•

After the screed is on the blocks, it must be nulled out. Nulling out the screed is an expression used to describe adjusting both ends of the screed so that the screed plate rests absolutely flat on the starting blocks. The screed will be nulled when the following conditions are satisfied. — Both front and rear edges of the screed rest squarely on the starting blocks. — Screed depth cranks have a limited amount of free rotary movement between screed tension in either direction. The presence of this limited free rotary movement is an indication that the screed is nulled out.

Initial Screed Angle-of-Attack

At this point, the screed angle-of -attack should be introduced. The weight of the screed exerts a compacting force as it passes over the bituminous mix. The angle-of- attack is an adjustment which raises the front edge of the screed causing the screed to climb enough to equal the amount of compaction that it exerts on the mix. Exact angle-of-attack is always an unknown factor since many factors, such as variation in the mix, composition, temperature and paving speed, all affect the amount of angle-of-attack required. However, it is known that there will be compaction by the screed making it necessary to introduce some angle-of-attack before the screed leaves the starting blocks. With the screed properly nulled out, introduce a start-up angle-of-attack by turning both screed depth cranks one full turn counterclockwise (CCW). When paving begins, check the mat depth and adjust the depth cranks until desired mat depth is obtained. Lighting the Screed Heater

!

WARNING

Fire Hazard Never fuel the machine while the screed heaters are operating. Never use the wash down system while the screed heaters are operating. Never attempt to relight the screed heaters for any reason until you are absolutely sure excess fuel has been removed from the burner interior and surrounding areas. Failure to observe this admonishment in its entirety may result in property damage, severe personal injury or even death. PF-161 Paver/Finisher

4-5

Section 4


!

CAUTION

Possible Equipment Damage The burners are intended for use during initial heating of the screed plate. During paving the material itself will keep the screed plate hot. Avoid overheating of the screed. Failure to adhere to this admonishment could result in equipment damage including warping of the screed plate and frame.

Before starting to pave with bituminous materials, the screed should be preheated. This hel ps to prevent the hot mix from sticking to a cold screed plate and encourages the production of a smooth tight mat. If the machine sits idle for a long period of time between loads, the screed should be pre-heated again. Allow 12-to-15 minutes for preheating a cold screed. Five-to-ei ght minutes will be sufficient when the screed has been sitting on warm material. NOTE: The heater circuit contains a timer switch which shuts off the fuel pump after a factory set period. This is to prevent overheating which could warp the screed plate. To reset this timer, cycle the fuel pump switch OFF then ON.

Light the screed heaters and preheat the screed as follows: NOTE: The below procedure addresses both the main and extension burners. If your vehicle does not use a screed extension, ignore the operation of the extension screed burner controls mentioned in the below procedure.

1. Check each of the fuel valve switches (68 and 59, Figure 4-1) (main and extension) to be sure they are in the DOWN or in the OFF position. 2. Turn on the Fuel Pump (63, Figure 4-1), the Main Blower (67, Figure 4-1), and extension blower switches (60, Figure 4-1) ON and allow them to operate for one minute to purge the system before lighting the burners.

4-6



Section 4

3. Turn both Burner Blower switches (67 and 60, Figure 4-1) OFF. Figure 4-1

4. Ignite the screed heaters one at a time as follows: •

If your screed uses a glow plug ignition, perform the following: — Run the paver engine at FULL RPM. — Hold the MAIN and EXTENSION Burner Switches (67 and 60, Figure 4-1) to IGNITER for 20 seconds. — Flip the FUEL Toggle Valves (68 and 59, Figure 4-1) to the Up or set to the On position to ignite the burners and to continue operating the respective screed heater. — Push the MAIN and EXTENSION Burner Switches (67 and 60, Figure 4-1) to BLOWER as soon as ignition takes place.

•

If your screed uses a spark type ignition, perform the following: — Press the MAIN and EXTENSION Burner Switches (67 and 60, Figure 4-1) to IGNITER (produces an arc between two electrodes) — Flip the FUEL Toggle Valves (68 and 59, Figure 4-1) to the up or press to the on position to ignite and continue operating the respective screed heater. — Switch the MAIN and EXTENSION Burner Switches (67 and 60, Figure 4-1) to BLOWER as soon as ignition takes place.

5. Adjust baffles on each burner unit, as required, to obtain maximum heat and clean burning flames inside of the burner chambers. Listen for a maximum roar and watch for minimum smoke as an indication of optimum combustion. 6. Run the vibrators while heating the screed. 7. Re-grease the vibrator drive shaft and U-joint bearings immediately after heating the screed.


4-7

Section 4


8. When the screed reaches operating temperature and the burners are no longer required, shut the burners down as follows: •

Turn the FUEL PUMP Switch (63, Figure 4-1) OFF.

•

Turn the MAIN and EXTENSION FUEL Valves (68 and 59, Figure 4-1) OFF.

•

Wait 5 minutes (allowing blowers to run).

•

Position the MAIN and EXTENSION Burner Switches (67 and 60, Figure 4-1) to the OFF position.

Positioning the Material Truck and Starting to Pave

The following is a guideline to aid in the initial placement of the material track in front of the PF-161 Paver/Finisher. It provides information regarding placement of the truck and the initial control setting for the machine to begin to receive material. 1. Position a truck loaded with paving material against the push rollers in front of the paver (1, Figure 4-2). Figure 4-2

4-8



Section 4

2. Set the throttle switch (32, Figure 4-3) on the main control panel to the AUTO (UP) position. Figure 4-3

3. Set the L.H. and R.H. Conveyor Switches (28, Figure 4-3) to the AUTO (LEFT) position. 4. Fill the hopper and allow the conveyors to automatically shutdown as the augers become full. 5. Set the Screed Vibrator Switch (30, Figure 4-3) to the AUTO (LEFT) position. 6. Verify that the Motor Shift Switch (21, Figure 4-3) is in the LOW position (not depressed). 7. Move the Direction Speed lever (3, Figure 4-4) FORWARD and begin to pave. Figure 4-4

8. As paving progresses, make adjustments necessary to maintain adequate material delivery and produce a satisfactory mat. Refer to the Paving Manual for information pertaining to controlling mat quality.


4-9

Section 4


OPERATING THE MACHINE - GENERAL GUIDELINES The following are general guidelines to be followed whenever you are operating the machine. Read and understand these guidelines thoroughly before attempting to operate the machine.

!

WARNING

Personnel Injury, Property Damage Do not allow untrained personnel to operate this machine. Even the seemingly simple task of relocating the machine could be hazardous if attempted by an untrained person. Failure to adhere to this admonishment could result in property damage, severe personnel injury or even death.

!

CAUTION

Equipment Damage Make sure you have preformed all the pre-checks required and that all equipment fluid levels are adequate. Failure to adhere to this admonishment could result in equipment damage, performance degradation or premature failure of mechanical components.

1. Always sound the horn before moving the machine in either direction to alert persons in the vicinity. Allow sufficient time for persons to move from the vehicle’s path before putting the machine into motion. This also verifies that the horn is operational. 2. Monitor all warning lights. If instruments or lights indicate a fault or problem, contact appropriate personnel to identify the problem and correct it. 3. Monitor and ensure that the horn and any optional lighting are operational. 4. Always move the steering wheel slowly and monitor the steering action. 5. Always fully depress the Engine Kill switch on the main control panel and remove the ignition key before leaving the operator station.

4-10



Section 4

MOVING THE MACHINE - UNDER PROPULSION Follow the below guidelines whenever moving the machine under it’s own propulsion. 1. Physically walk around the paver, ensuring that no one is in the area, all components are secure and that nothing is under or in the way of the wheels.

!

WARNING

Personnel Injury, Property Damage Do not allow untrained personnel to operate this machine. Even the seemingly simple task of relocating the machine could be hazardous if attempted by an untrained person. Failure to adhere to this admonishment could result in property damage, severe personnel injury or even death.

!

CAUTION

Equipment Damage Make sure you have preformed all the pre-checks required and that all equipment fluid levels are adequate. Failure to adhere to this admonishment could result in equipment damage, performance degradation or premature failure of mechanical components.

2. Mount the machine using the steps and handrail provided at the rear of the machine. Remember to maintain three-point contact while you are climbing onto or off of the machine. 3. Unlock and open the cover to gain access to the main control panel. 4. Get seated on the side of the machine that will offer you the most beneficial view, taking into account the terrain and obstacles in your area. 5. Position the main control panel in a suitable position for the side of the machine you are seated. 6. Position the Direction Speed control lever (3, Figure 4-4) to the NEUTRAL (centered) position. 7. Place all control switches on the main control panel to the OFF or centered position.


4-11

Section 4


8. Position the THROTTLE Switch (32, Figure 4-5) to the IDLE (center) position. Figure 4-5

9. Position the TRANSMISSION SHIFT Switch (20, Figure 4-5) to the LOW position. 10. Position the MOTOR SHIFT Switch (21, Figure 4-5) to the LOW position. 11. At the Direction/Speed Control Lever (3, Figure 4-4) to be used, rotate the hinged lockout plate out of the way, so that the lever is free to move into the reverse range. 12. Pull the Engine Kill Button (19, Figure 4-5) all the way out. 13. Depress the STARTER Button (18, Figure 4-5). The engine should start and come up to speed. Note that the engine will NOT START if the Directi on/Speed Control Lever is not in the NEUTRAL position. 14. Wait approximately three minutes for the engine to warm up.

4-12



Section 4

15. Raise the screed to a position above the ground using the Screed Control switch (24, Figure 4-5). Make sure the screed cylinders are retracted sufficiently to engage the locking support brackets (1, Figure 4-6). Figure 4-6

16. Return the SCREED Control Switch (24, Figure 4-5) to the HOLD (center) position. 17. Manually secure the screed in it’s elevated position by engaging the locking support brackets (1, Figure 4-6) on the left-hand and right-hand screed cylinders. 18. Move the machine by moving the Direction/Speed Control Lever (3, Figure 44) in the FORWARD or REVERSE direction, as needed. Note that the further the Direction/Speed Control Lever is moved from NEUTRAL, the greater the machine velocity will be. 19. To stop the machine, bring the Direction/Speed Control Lever back to the NEUTRAL position.


4-13

Section 4


20. If you are moving the machine over a distance that would make a higher velocity desirable, keep the following facts in mind: •

The Engine GOVERNOR Switch (31, Figure 4-7) controls maximum engine RPM at full throttle. Pave is 1800 RPM, while Travel is 2200 RPM. Figure 4-7

•

The THROTTLE Switch (32, Figure 4-7) is a three-position switch used to select engine throttle speeds. The center position is IDLE (1000 RPM), UP is the AUTO position which allows for engine speed to be governed by load and transmission settings, while the lower position is MANUAL which means the governor has engine speed control totally.

•

The MOTOR SHIFT Switch (21, Figure 4-7) is a push-button. This switch controls the 2-speed traction drive motors in each final drive between HIGH and LOW. Extended is in the LOW setting while depressed is the HIGH setting. It is not necessary to stop the machine before shifting the traction drive motors between HIGH and LOW.

!

CAUTION

Possible Transmission Damage. Never switch the transmission when the machine is moving. Failure to adhere to this Caution may result in damage to the transmission.

4-14



Section 4

•

The TRANSMISSION SHIFT Switch (20, Figure 4-7) is used to shift the twospeed transmission units in each final drive between HIGH and LOW.

•

Various combinations of these switch positions will allow for various travel/paving speeds. Below is a list of such speeds:

•

Low Motor/Low Transmission

- 0-36 m/min (0-119 fpm) @ 2100 rpm

•

High Motor/Low Transmission

- 0-94 m/min (0-312 fpm) @ 2100 rpm

•

Low Motor/High Transmission

- 0-7.6 km/hr (0-4.7 mph) @ 2100 rpm

•

High Motor/High Transmission

- 0-19.9 km/hr (0-12.7 mph) @ 2100 rpm

•

Reverse

- Full reverse in any of the four speed ranges

MOVING THE MACHINE BETWEEN WORKSITES Before driving the machine on public roads, check with your supervisor for instructions and information in respect to traffic regulations regarding construction machinery. NOTE: For more information on transporting, refer to Section 1, SAFETY Precautions and Guidelines.

1. Clean the paver/finisher. Refer to the procedures outlined in the Maintenance Section of this manual. Make sure it is free of debris that could become a hazard to other vehicles as it is being moved. 2. Choose level ground which will solidly support the vehicle. 3. Clean the trailer and loading ramps. 4. Chock the wheels of the trailer before attempting to load the machine. 5. Approach the transporter loading ramp squarely to make sure the paver/ finisher does not drop off the side of the ramp. 6. Drive the paver/finisher onto the transporter. 7. Shut the engine off, remove the keys and lock all lockable compartments. 8. Apply the necessary road warnings to the machine. You will need to enlist the help of a qualified signalman to accomplish this task.

Securing the Machine to the Transporter (Tiedown) 1. Chock all wheels. 2. Tie down machine using a chain and tensioning device or other appropriate equipment to tie-down points. 3. Make sure the driver of the transport is aware of the paver/finisher’s total weight, load on the axles and overall machine dimensions.


4-15

Section 4


TOWING THE MACHINE

!

CAUTION

Equipment Damage Never highway tow the paver/finisher with the drive wheels on the ground. Failure to adhere to this admonishment will result in destruction of the final drive planetary.

These towing instructions are intended to provide information pertaining to moving a disabled paver/finisher under emergency circumstances a short distance only (off the job site, etc.) to a transport vehicle. Towing speeds shall never exceed 1.6 kph (1 mph) under any circumstances. The paver/finisher can be moved even if the hydrauli c system does not have enough pressure to disengage the parking brake by using the manual hand pump and brake release valve described in the procedure below. Never attempt to release the parking brake except under these emergency conditions. Perform the procedure outlined below to tow the paver/finisher.

!

CAUTION

Property Damage Never use a flexible towing device, such as a chain, cable or straps. Failure to adhere to this admonishment could result in a collision between the paver/finisher and the towing vehicle causing damage to both vehicles.

1. Attach a properly sized tow bar to the paver/finisher and an appropriate towing vehicle. 2. Engage the brakes on the towing vehicle so that it does not begin to roll when the paver/finisher’s brakes are released.

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Section 4

3. At the Main control panel, fully depress the Engine Kill button (19, Figure 4-8). Figure 4-8

4. Remove the left deck plate and gain access to the hydraulic hand pump (1, Figure 4-9) and the brake release valve (2, Figure 4-9). Figure 4-9


4-17

Section 4


!

WARNING

Personnel and Property Hazard Never close the brake release valve, except to release the brakes for emergency towing. The brakes cannot be reapplied from the operator’s station once they have been released. Failure to adhere to this admonishment may result in the paver/finisher free-rolling out of control causing property damage and possibly inflicting serious injury or even causing death.

5. Close the brake release valve (2, Figure 4-9) by pushing it down and holding it in place. 6. While holding the brake-release valve down, use the hand pump (1, Figure 49) to release the brakes. The brakes will become fully released when the hydraulic pressure reaches 400 psi. This normally requires 35-to-40 full strokes. 7. After the paver/finisher has been towed to the desired location, perform the following:

4-18

•

Place chocks under each wheel.

•

Open the brake release valve by pulling it up.


SECTION 5 - MAINTENANCE INSTRUCTIONS


5-1

Section 5


MAINTENANCE INSTRUCTIONS GENERAL This section contains general maintenance instructions for the PF-161 Paver/Finisher. These instructions are broken down into the following categories: •

Clean-up and Washdown

•

Periodic Maintenance

•

Off-Season Storage

NOTICE Read and understand all instructions contained in this manual, the engine manual and any other pertinent manuals before attempting to service this paver/finisher. Paver/finisher adjustments and servicing shall be performed only by qualified individuals who have been properly trained and are authorized to do so.

!

WARNING

Equipment Damage/Personnel Injury Always mount and dismount the paver/finisher from the rear using walkways, steps and handrails provided. Failure to observe this admonishment could result in equipment damage or bodily injury.

5-2



Section 5

!

WARNING

Personnel Hazard/Equipment Damage Before attempting to service, attach or remove any part or assembly on the paver/finisher, make certain that: 1. All controls and switches are in the OFF or centered position. 2. Hopper wings are lowered. 3. Screed is lowered or secured in the raised position. 4. Engine is shut off unless otherwise instructed. Failure to comply with these instructions could result in equipment damage, bodily injury or even death.

!

WARNING

Fire Hazard Refuel the paver/finisher only when the engine in not running. DO NOT permit sparks, open flames or smoking within 15.2 m (50 ft.) of the paver/ finisher when refueling. Never refuel paver/finisher with screed heaters operating. Never use the WASHDOWN system when screed heaters are operating. Failure to comply with these guidelines could result in a fire, causing property damage, severe bodily injury and possibly death.


5-3

Section 5


!

WARNING

Bodily Injury - Escaping hydraulic fluid under pressure can have sufficient force to penetrate the skin causing serious personal injury. See a doctor immediately if you are ever injured by escaping hydraulic fluid. Serious infection or reaction can develop if proper medical treatment is not administered immediately. Before disconnecting a hydraulic line, be sure to relieve all pressure. Before pressurizing a system, be sure all connections are tight and that lines, tubes and hoses are not damaged. Fluid escaping from a small hole can be nearly invisible. Use a piece of cardboard or wood rather than hands to search for suspected leaks. Failure to comply with these guidelines could result in a very serious injury, including blindness, infection or other adverse reaction.

!

WARNING

Burn Hazard Always open the radiator using work gloves or a heavy rag. Wear eye protection. Turn the radiator cap slowly to the stop and allow any pressure or steam to escape through the overflow hose. After all pressure is removed, finish removing the cap. Refill the radiator only when the engine is stopped or idling slowly. Pour coolant slowly until level is 25 mm (1 in.) below the bottom of the filler neck. Failure to comply with these guidelines could result in severe burns, eye injury or even blindness.

5-4



Section 5

!

WARNING

Explosion Hazard Batteries produce explosive gases. Keep sparks and open flames away from batteries. If a battery needs recharging, avoid sparks by turning off the charger before making connections or disconnections. Failure to comply with these guidelines could result in an explosion causing severe bodily injury and even death.

!

WARNING

Chemical Hazard Sulfuric acid in batteries is both toxic and caustic. Contact with skin will cause severe chemical burns. Avoid all contact with skin, eyes and clothing. When working around batteries, wear gloves, eye and face protection. Failure to observe these guidelines may result in severe chemical burns, poisoning, eye injury and even blindness.

!

WARNING

Toxic Gases Engine exhaust is toxic and potentially fatal. Before starting the engine, be sure there is adequate ventilation. If it is necessary to operate the vehicle inside an enclosed service area, make sure exhaust fumes are well ventilated. Failure to adhere to these guidelines could result in illness or physical damage or even death.


5-5

Section 5


!

WARNING

Moving Equipment Verify that all personnel are clear of the paver/finisher before starting so they cannot be struck by or caught in moving parts. Failure to adhere to this admonishment could result in bodily injury or even death.

CLEAN UP AND WASHDOWN This procedure shall be followed at the end of each work day while the paver/finisher is still warm. Keeping the paver/finisher cleaned and washed down with diesel fuel, kerosene or another appropriate cleaning solution will ensure it’s proper performance and maximum service life. Keeping the paver/finisher clean is an especially effective means of extending the operating life of components in the material handling areas. Abrasive materials which accumulate in the sprocket, bearing and auger and conveyor areas all increase stress on components and accelerate wear. Daily cleaning and washdown practices also promote trouble-free mat production. Cold paving material can break loose and produce tears in the mat as they pass under the screed. All residual asphalt materials shall be removed from the paver/finisher, especially in the material handling areas and these surface shall be sprayed to eliminate any remaining residue. The resulting petroleum film residue left behind after clean up and washdown reduces the potential for material sticking the next time the paver/finisher is used. Perform the steps outlined below to cleanup and washdown the paver/finisher.

NOTICE Perform this procedure only in authorized/designated areas. Performance of this procedure in areas other than those approved of by your organization could result in serious criminal violations of environmental regulations. 1. Drive the paver/finisher to the designated clean up and washdown area. 2. Clear the immediate area around the paver/finisher. 3. Lower hopper wings. 4. Secure screed in the raised position. 5. Position all operation switches to the OFF or centered position on the main control panel.

5-6



Section 5

6. Fully depress the Engine Kill Button (19, Figure 5-1). Figure 5-1

!

WARNING

Fire Hazard Never use the WASHDOWN system when screed heaters are operating. Failure to comply with these guidelines could result in a fire, causing property damage, severe bodily injury and possibly death.


5-7

Section 5


7. Wait 10 minutes while the screeds cool.

!

WARNING

Fire and Personal Injury Diesel fuel is both flammable and slippery, so extreme care must be exercised during this clean up and washdown proced ure to avoid fire and personal injury. Verify that the screed heaters are turned off and have cooled sufficiently. Run the conveyors and augers only when required to gain access to all surfaces and only after personnel are out of the material handling areas. Never stand on augers, auger tunnels, auger guards or edger-plate assemblies. Never smoke or allow others to smoke while performing this procedure. Turn the FUEL PUMP Switch on only IMMEDIATELY before you start to use the WASHDOWN hose. Turn the FUEL PUMP Switch off IMMEDIATELY after use of the WASHDOWN hose is completed. Failure to adhere to these guidelines could result in falling, fire, and/or explosion which could cause severe personal injury and even death. 8. Turn the FUEL PUMP Switch (63, Figure 5-2) on. This switch is located on the right-hand (R.H.) screed control box. Figure 5-2

5-8



Section 5

9. Position the WASHDOWN Hose Valve (1, Figure 5-3) to the on position. Note that this valve is located next to the WASHDOWN Hose (2, Figure 5-3), which is located on the R.H. side of the paver/finisher. Figure 5-3

10. Pull the WASHDOWN Hose (2, Figure 5-3) out far enough so that the components on the paver/finisher that need to be washed are accessible. Be careful not to kink or damage the hose.


5-9

Section 5


11. Starting at the front of the paver/finisher and working your way back, spray down the paver/finisher. Refer to Figure 5-4 and Figure 5-5 for diagrams of the paver/finisher that point out areas that typically require extra attention. Figure 5-4

12. Be sure to spray down all surfaces that come in contact with paving material, including push-rollers, hopper surfaces, flowgates, conveyors, augers, screeds (both main and extendible sections), edger-plates and deck areas. 13. Use a scraping device to remove accumulated material. You may need to attach a long handle to your scraping device to reach all areas safely that require scraping. 14. Push-rollers (1, Figure 5-4): •

Remove all built-up material on the rollers and mounts

•

Rotate the rollers while cleaning and soak bearing ends to maintain free rotation.

!

WARNING

Personal Hazard Do not enter hopper while engine is running. Potential for moving parts causing severe injury is very high. Failure to comply with this admonishment could result in serious injury.

5-10



Section 5

15. Hopper surfaces and flow gates (2 and 4, Figure 5-4): •

Clean all hopper surfaces thoroughly.

•

Lower flow gates to clean the surfaces and raise them to gain access to the conveyor tunnels. Figure 5-5

!

WARNING

Personal Injury Hazard. Do not run conveyors while using scraper to remove paving material. Have a qualified operator at the control station at all times during this procedure. Stand in full view of the operator while cleaning. Never enter the hopper while the engine is running. Never stand in the auger-trough area. Failure to observe these guidelines could result in severe injury, loss of limb or even death.


5-11

Section 5


16. Conveyors (3, Figure 5-4): •

Raise hopper apron to remove material which has accumulated around the idler shaft and front conveyor bearings.

•

Stand on the ground at a safe distance and spray moving conveyor chains and bars.

•

Clean rear-drive sprockets and tunnel areas thoroughly.

•

Run conveyors after washdown to carry solvent into conveyor return areas under the floor plates to help dissolve hidden asphalt.

!

WARNING

Personal Injury Hazard. Never stand in the auger-trough area. Never run the augers while using the scraper to remove paving material. Have a qualified operator at the control station at all time during this procedure. Stay in full view of the operator while cleaning. 17. Augers, auger bearings, auger tunnels and auger guards (6, Figure 5-4): •

Clean auger surfaces thoroughly.

•

Scrape out accumulated material around bearings.

•

All material contact surfaces must be cleaned down to the metal to avoid quick build-up when paving resumes.

18. Screed (8, Figure 5-4 and 12, Figure 5-5): •

Face and bottom plates shall be clean and smooth on both the main and extendible sections.

!

WARNING

Personal Injury Hazard. Never disassemble or assemble edger-plate assemblies while augers are running. Failure to comply could result in severe personal injury, loss of limb or even death.

5-12



Section 5

19. Edger-plates (7, Figure 5-4 and 11, Figure 5-5): •

Remove and clean so they slide freely on the paver/finisher while the augers are running.

20. Deck areas (5, Figure 5-4 and 9, Figure 5-5): •

Remove all paving material and then, carefully remove solvent residue, so that walking surfaces are not slippery.

PERIODIC MAINTENANCE Periodic maintenance is typically preventative in nature and is scheduled to keep the paver/ finisher in proper operating condition. Failure to perform this maintenance at the recommended intervals will result in unanticipated paver/finisher failure and loss of use. All of these tasks are to be performed at a predetermined interval. Some are daily, while others are performed weekly or even yearly. Many of these tasks involve t he application of lubricants while others are adjustments. To perform these tasks effectively, refer to the schedule of maintenance provided later in this section. This schedule refers to specific tasks, recommended performance intervals and references a procedure to follow in order to perform the required tasks. Prior to attempting to perform any task, read and understand the paragraph below regarding lubricants. Compliance with this information is critical.

Lubricants Use quality lubricants furnished by reliable manufacturers or as specified in Table 5-1 below. Use the proper lubricant for each application as specified. DO NOT MIX LUBRICANTS.

!

CAUTION

Possible Equipment Damage. Power grease guns can blow out and permanently damage bearing seals. If power grease guns must be used, use power guns for very short bursts of one second or less with five second delays between bursts to allow grease to escape slowly. Failure to observe this admonishment may result in equipment damage and subsequent major mechanical failure. Most bearings on the paver/finisher are permanently sealed and require no greasing. For those bearings that do require hand greasing, the use of a hand grease gun is recommended. Escaping grease should not be visible around the bearings or felt washers.


5-13

Section 5


Perform lubrication at the end of the day while the paver/finisher is warm. This will insure that the lubricant reaches all critical points. Store lubricants in clean, covered containers. Make certain that funnels, measures and all other equipment are cleaned before and after use. Clean fittings, plug openings and other lubrication points before servicing. Inspect and clean plugs and other detachable fittings before reinstalling. Frequency requirements listed in the Lubrication and Service Schedule are based on normal operating conditions. Check filters more frequently if operating in very dusty conditions.

Table 5-1: Approved Lubricants Extreme Pressure Gear Lubricant

Extreme Pressure Multipurpose Grease

SAE 85W-140, API GL-5,

Synthetic Component Lubricant (Synthetic Hydrocarbon w/Phosphorus) ISO Viscosity Grade - 220

NLGI EP2

Viscosity Index - 152

MIL-PRF-2105E

LUBRICATION AND SERVICE SCHEDULE Periodic lubrication and service is divided into separate categories by frequency intervals. The following paragraph discuss these requirements. Table 5-2 through Table 5-7 provide lists of these tasks by interval. A list of periodic maintenance tables is provided below.

5-14

•

Table 5-2. Daily Maintenance Requirements

•

Table 5-3. Weekly Maintenance Requirements

•

Table 5-4. Quarterly Maintenance Requirements.

•

Table 5-5. Semi-Annual Maintenance Requirements.

•

Table 5-6. Annual Maintenance Requirements.

•

Table 5-7. Miscellaneous Maintenance Tasks



Section 5

Daily Maintenance Requirements Table 5-2 below list maintenance tasks that shall be performed on a daily basis. These tasks shall be performed at the end of each w ork day. This will ensure fluid lev els are checked when the equipment is warm and provide for correct levels at the beginning of each work day.

Table 5-2: Daily Lubrication and Service Lube or Service Point

Service

Page No.

Front Conveyor Bearings

Grease

page 5-20

Rear Conveyor Bearings

Grease

page 5-20

Auger Bearings

Grease

page 5-21

Screed Vibrator Shaft Bearings

Grease

page 5-21

Hydraulic Fluid

Check Level

page 5-21

Engine Oil

Check Level

page 5-23

Engine Radiator

Check Level

page 5-24

Cooling Fan

Inspect

page 5-26

Truck Hitch Option Rollers

Grease

page 5-27

Engine Air Intake Piping

Inspect

page 5-27

Drive Belts

Inspect

page 5-28

Drain

page 5-28

Inspect

page 5-28

Inspect Adjust

page 5-29

Fuel Water Separator Crankcase Breather Tube Conveyor Chains


5-15

Section 5


Weekly Maintenance Requirements Table 5-3 below lists maintenance tasks that shall be performed on a weekly basis or after every 40 hours of operation, whichever comes first. These tasks shall be performed at the end of a work day. This will ensure that the equipment is warm, thus ensuring adequate flow and distribution of lubricants being applied.

Table 5-3: Weekly Lubrication and Service Lube or Service Point

Service

Page No.

Clean/Grease

page 5-31

Screed Depth Cranks

Grease

page 5-32

Screed Pivot Points

Grease

page 5-33

Front Wheel King Pins

Grease

page 5-34

Front Wheel Bogie Pivot Bearings

Grease

page 5-35

Truck Hitch Option Sides

Monthly Maintenance Requirements Monthly maintenance is limited to an operational check of the parking brake system (page 535). Later in this section a procedure is provided for the performance of this operational check.

Quarterly Maintenance Requirements Table 5-4 below list maintenance tasks that shall be performed on a quarterly basis or after every 250 hours of operation, whichever comes first. These tasks shall be performed at the end of a work day. This will ensure that the equipment is warm, thus ensuring adequate flow and distribution of lubricants being applied.

Table 5-4: Quarterly Lubrication and Service Lube or Service Point

Service

Page No.

Engine Oil and Filter

Change

page 5-38

Air Cleaner

Change

page 5-41

Short Coupled Drive Shaft

Grease

page 5-46

Radiator Hoses

Check

page 5-46

Fuel Pump

Check

page 5-46

Check/Adjust

page 5-47

Auger Sections

Inspect

page 5-48

Hopper Hinge Assembly

Inspect

page 5-48

Auger/Conveyor Drive Chains

5-16



Section 5

Semi-Annual Maintenance Requirements Table 5-5 below list maintenance tasks that shall be performed on a semi-annual basis or after every 500 hours of operation, whichever comes first.

Table 5-5: Semi-Annual Lubrication and Service Lube or Service Point Hydraulic Fluid and Filters Engine Coolant

Service

Page No.

Change

page 5-49

Check

page 5-57

Annual Maintenance Requirements Table 5-6 below lists maintenance tasks that shall be performed on an annual basis or after every 1000 hours of operation, whichever comes first. These tasks shall be performed at the end of a work day. This will ensure that the equipment is warm, thus ensuring adequate flow and distribution of lubricants being applied.

Table 5-6: Annual Lubrication and Service Lube or Service Point

Service

Page No.

Repack

page 5-59

Pump Drive Box

Change Fluid

page 5-59

Auger/Conveyor Planetaries

Change Fluid

page 5-61

Drive Wheel Planetaries

Change Fluid

page 5-62

Engine Fuel Filter

Change

page 5-63

Washdown Fuel Filter

Change

page 5-66

Front Bogie Wheels


5-17

Section 5


Miscellaneous Maintenance Tasks Table 5-7 below lists maintenance tasks that do not fall into a specific category and should be performed on an “as needed” basis.

Table 5-7: Miscellaneous Maintenance Tasks Lube or Service Point

Service

Page No.

Hopper Wiper Arms

Adjustment

page 5-68

Swing Console

Adjustment

page 5-68

Steering Consoles and Seats

Adjustment

page 5-69

Hopper Side Extensions

Adjustment

page 5-70

Servicing and Hydroinflation

page 5-70

Drive Tires

Preventative Maintenance Checklist The following list is provided as a guide for periodic inspection and maintenance of the PF-161 Paver/Finisher. Establishing and performing a program of preventative maintenance will prevent normal wear from becoming a major expense. 1. Lubricate this paver/finisher completely in accordance with the Lubrication and Service Schedule (Table 5-2 through Table 5-7). Always perform lubrication when the paver/finisher is still warm. 2. Check engine oil for correct operating level and change as recommended. Keep cooling fins in engine cylinders and heads clean. Blow out dust with compressed air occasionally. Keep battery filled to proper level. Refer to Engine Maintenance and Operator’s Manual for complete servicing information. 3. Tighten all hydraulic hoses and fittings before putting the paver/finisher in service. After the first day of operation, check for leaks and retighten hoses as necessary. Always be on the lookout for hydraulic leaks. When hydraulic leaks are discovered, correct them immediately to prevent damage to hydraulic components. Check hoses for cracks and/or abrasions. Replace hoses that are worn or damaged. 4. Check the hydraulic reservoir regularly for proper level and clean fluid. Change fluid and filters and clean strainers as directed in the Lubrication and Service Schedule (Table 5-2). 5. Check for proper brake operation as prescribed in the procedure titled PARKING BRAKE, later in this section (page 5-35).

5-18



Section 5

6. Check and adjust the conveyors per the instructions titled ADJUSTMENT OF CONVEYOR CHAINS, later in this section. Conveyor chains are the most expensive wear item on the paver/finisher. Consequently, proper adjust ment is extremely important in terms of obtaining maximum service life from these components. 7. Check and adjust Auger/Conveyor drive chain tension per the instructions titled ADJUSTMENT OF AUGER/CONVEYOR DRIVE CHAINS, later in this section. 8. Inspect the cast auger sections for wear. Replace if badly worn or broken. 9. Check the screed regularly for worn parts per the instructions titled CHECKING SCREED WEAR later in this section. Refer to the paving manual for screed adjustment and operating procedures that will help you get the maximum life out of your screed. 10. Inspect hopper hinge assemblies. These assemblies may develop extensive wear after considerable use. Repair or place these components as necessary. 11. Wash the paver/finisher down completely after each use in accordance with the procedures titled CLEAN UP AND WASHDOWN earlier in this section. 12. Check the condition of wiring harnesses and battery cables regularly. Replace wiring if insulation is worn or damaged and ensure that all connections are clean and tight.

MAINTENANCE INSTRUCTIONS The following instructions support the tasks you have been instructed to perform on the previous pages, either in the Lubrication and Service Schedule or the Preventative Maintenance Checklist. Only qualified personnel who have been properly trained on this equipment shall perform these procedures. The following maintenance instructions are divided into the same categories as they are in Table 5-2 through Table 5-6 (Daily, Weekly, Monthly, Quarterly, Semi-Annually and Annually). Read this section in it’s entirety before attempting to perform any of the work prescribed in this section.

Daily Maintenance Tasks The following tasks shall be performed on a daily basis, before attempting to operate the paver/finisher.


5-19

Section 5


Front Conveyor Bearing - Grease Lubricate the front conveyor bearings (1, Figure 5-6) using approved lubricant from Table 5-1 at the end of each day’s operation while the paver/finisher is still warm. Figure 5-6

Rear Conveyor Bearings - Grease Lubricate the rear conveyor bearings (1, Figure 5-7) using approved lubricant from Table 5-1 at the end of each day’s operation while the paver/finisher is still warm. Figure 5-7

5-20



Section 5

Auger Bearings - Grease Lubricate the auger bearings (1, Figure 5-8) using approved lubricant from Table 5-1 at the end of each day’s operation while the paver/finisher is still warm. Figure 5-8

Screed Vibrator Shaft Bearings - Grease Lubricate the screed vibrator shaft bearings (1, Figure 5-9) using approved lubricant from Table 5-1 at the end of each day’s operation while the Paver/Finisher is still warm. Figure 5-9

Hydraulic Fluid - Check Level The hydraulic fluid level shall be checked daily. Fluid level in the hydraulic system may be checked whether the system is running or not. Perform the following steps to check the level of hydraulic fluid in the system.


5-21

Section 5


!

CAUTION

System Contamination Use care to prevent debris from entering the hydraulic tank when the cap is removed. Even small amounts of contaminants will cause the system to prematurely fail. Failure to observe this admonishment may result in hydraulic system failure. 1. Place the vehicle on level terrain. 2. Remove the fill cap (1, Figure 5-10) on the hydraulic tank. Figure 5-10

3. Wipe off the dipstick (2, Figure 5-10) with a clean rag or paper towel. 4. Insert the dipstick. 5. Pull the dipstick out and observe the reading. The hydraulic fluid must be present to the correct level mark on the dipstick (2, Figure 5-10).

!

CAUTION

System Damage Only use approved hydraulic fluid in this system. Refer to Table 5-1 in this section for a list of approved fluids. Failure to observe this admonishment could result in system failure and/ or void warranties.

5-22



Section 5

6. If necessary, add hydraulic fluid to the system directly through the opening at the fill cap. 7. Screw the fill cap/dipstick assembly back on the fill tank opening.

Engine Oil - Check Level The lubricating engine oil level shall be checked daily. If more detailed information is required, refer to the Engine Operation and Maintenance Manual. To check the level of lubricating engine oil take the following steps: 1. Position the vehicle on level terrain. 2. Shut the engine off and wait at least 15 minutes. 3. Pull out the oil indicator dipstick (1, Figure 5-11) and wipe it off with a clean rag or paper towel. Figure 5-11

4. Reinsert the dipstick and pull back out for an accurate reading. 5. Oil level should be indicated up to the full level mark on the dipstick.

!

CAUTION

Engine Damage Use only approved lubricants in this engine. Refer to Table 5-1 for a list of approved lubricants. Failure to observe this admonishment could result in engine failure and/ or void warranties. 6. Add oil, as necessary, through the fill cap (2, Figure 5-11) on the engine until the oil level returns to the full mark on the dipstick.


5-23

Section 5


Engine Radiator - Check Level The coolant level shall be checked daily. If more detailed information is required, refer to the Engine Operation and Maintenance Manual. To check engine coolant level, perform the following steps:

!

WARNING

Personal Injury Never remove a pressure cap from a hot engine. Wait until the engine has cooled to 50° C (120° F) or less before removing the pressure cap. Always remove the pressure cap slowly, allowing any steam to escape before fully removing the cap. Always wear safety glasses and gloves. Failure to observe this admonishment could result in serious burns to the face including your eyes resulting in possible blindness.

!

CAUTION

Equipment Damage Never use a sealing additive to stop leaks in the cooli ng system. This can result in plugging of the cooling system, which over time, will restrict system flow and compromise the system’s ability to cool the engine. Failure to observe this admonishment could result in overheating of the engine, eventual premature engine failure and could void you warranties.

5-24



Section 5

1. Slowly remove the pressure cap (2, Figure 5-12) from the radiator (1, Figure 512) after the water in the radiator has cooled. Figure 5-12

2. Visually inspect the level of coolant in the radiator. The coolant should come up to the bottom of the fill neck. 3. If the level of the coolant is low, perform the following steps to add coolant to the system:

!

CAUTION

Engine Damage Never add cold coolant to a hot engine. Allow the engine to cool below 50° C (120° F) before adding coolant. Failure to observe this admonishment may result in damage to the engine castings. •

Create a sufficient volume of a 50%-water and a 50%-approved glycol coolant mixture.

•

Add this mixture to the radiator until it reaches the fill neck of the radiator.

4. Reinstall the pressure cap on the radiator.


5-25

Section 5


Cooling Fan - Inspect The cooling fan shall be inspected daily. If more detailed information is required, refer to the Engine Operation and Maintenance Manual. To check the cooling fan, perform the following steps: 1. Gain access to the engine and cooling fan by opening both sides of the engine cover. 2. Visually inspect the fan (1, Figure 5-13) for cracks, loose rivets and bent or loose blades. Figure 5-13

3. Check to make sure the fan is securely mounted and tighten the capscrews, if necessary. 4. If you note any problems, report your findings to the appropriate maintenance personnel to arrange for equipment repair.

5-26



Section 5

Truck Hitch Option Rollers - Grease Lubricate the rollers on the truck hitch option (1, Figure 5-14) using approved lubricant from Table 5-1 at the end of each day’s operation while the paver/finisher is still warm. Figure 5-14

Engine Air Intake Piping - Inspect The Engine Air Intake Piping shall be inspected daily. If more detailed informat ion is required, refer to the Engine Operation and Maintenance Manual.To chec k the Engine Air Intake Piping, perform the following steps: 1. Gain access to the engine by opening both sides of the engine cover. 2. Visually inspect the Engine Air Intake Piping (1, Figure 5-15) for wear points and damage to piping, loose clamps or punctures that c an damage the engine. Figure 5-15

3. Report discrepancies immediately to maintenance personnel so that the proper repairs can be performed in a timely manner.


5-27

Section 5


Drive Belts - Inspect The Drive Belts shall be inspected daily. If more detailed information is required, refer to the Engine Operation and Maintenance Manual. To check the Drive Belts, perform the following steps: 1. Gain access to the engine by opening both sides of the engine cover. 2. Check the drive belts for the following: •

Intersecting cracks

•

Longitudinal (along the belt width) cracks

•

Missing pieces of a belt

•

Frayed belt material

3. If any of the above conditions exist, contact service personnel immediately so that timely repairs can be made.

Fuel Water Separator - Drain Drain the fuel water separator (1, Figure 5-16) into a container on a daily basis. Dispose of drainage in accordance with local environmental regulations. Figure 5-16

Crankcase Breather Tube - Inspect Visually inspect the crankcase breather tube for excessive sludge, debris or ice. During periods of cold weather operation inspect the Crankcase Breather Tube more frequently throughout the day.

5-28



Section 5

Conveyor Chains - Inspect/Adjust Maintaining the paver/finisher’s two conveyors in proper adjustment will insure maximum service life from the conveyor chains, sprockets and shafts. A properly adjusted conveyor chain clears the ground a minimum of 127 mm (5 in.) between the drive wheels as illustrated in Figure 5-17. Figure 5-17

Adjustment of the conveyor chains is accomplished by moving the conveyor idler shaft and bearing arrangements, which are located under the hopper apron.

!

WARNING

Personal Injury Hazard Do not adjust conveyors while the engine is running. The chains could move catching and cutting parts of your body. Failure to observe this admonishment could result in serious injury.


5-29

Section 5


Perform the steps outlined below to adjust the conveyors: 1. Raise the hopper apron (1, Figure 5-18). Figure 5-18

NOTE: Use care to adjust both sides of the conveyor equally. This will prevent binding as the conveyor operates. NOTE: On new paver/finishers, it may be necessary to perform this adjustment several times during the break-in period to compensate for chain run-in. This requirement will diminish as the chain is run-in and only periodic observation will be required. NOTE: Note that as the chain is worn, maintaining the proper adjustment may use up all the adjustment travel. If this becomes the case, remove some chain links. This will allow you to effectively regain the required travel.

5-30



Section 5

2. Move the inner and outer-conveyor idler bearings (1, Figure 5-19) forward or rearward as required by turning the conveyor adjuster screws (2, Figure 5-18 and Figure 5-19) to obtain the necessary 127 mm (5 in.) minimum ground clearance. Figure 5-19

Weekly Maintenance Tasks The following maintenance tasks shall be performed at the end of the first day of each operational week (40 hour period, not calendar week).

Truck Hitch Option Slides - Clean/Grease Clean and lubricate the slides on the truck hitch option (1, Figure 5-20) using approved lubricant from Table 5-1 at the end of the first day of each work week (40 hour operational period). Perform this task while the paver/finisher is still warm. Figure 5-20


5-31

Section 5


Screed Depth Cranks - Grease Lubricate the screed depth cranks (1, Figure 5-21) using approved lubricant from Table 5-1 at the end of the first day of each work w eek (40 hour operational period). Perform this task whil e the paver/finisher is still warm. Figure 5-21

5-32



Section 5

Screed Pivot Points - Grease Lubricate the screed pivot points (1, Figure 5-22) using approved lubricant from Table 5-1 at the end of the first day of each work w eek (40 hour operational period). Perform this task while the paver/finisher is still warm. Figure 5-22


5-33

Section 5


Front Wheel King Pins - Grease Apply approved lubricant (Table 5-1) to the front wheel king pin lubrication points (1 and 2, Figure 5-23) at the end of the first day of each work week (40 hour operational period). Perform this task while the paver/finisher is still warm. Figure 5-23

5-34



Section 5

Front Wheel Bogie Pivot Bearings - Grease Apply approved lubricant (Table 5-1) to the front wheel bogie pivot bearings lubrication point (1, Figure 5-24) at the end of the first day of each work week (40 hour operational period). Perform this task while the paver/finisher is still warm. Figure 5-24

Monthly Maintenance Tasks Monthly maintenance is limited to an operational check of the parking brake.

Parking Brake - Operational Check The following procedure checks the parking brake for proper operation. This check shall be performed once per month, regardless of operational hours. Perform the steps outlined below to check the operation of the parking brake. 1. Position the paver/finisher on level ground.


5-35

Section 5


2. With the engine running, position the Direction/Speed Lever (2, Figure 5-25) to the NEUTRAL position. Figure 5-25

3. Position the PARKING BRAKE Switch (29, Figure 5-26) to the ON position. This will cause the brake to be applied. Figure 5-26

5-36



Section 5

!

WARNING

Personal/Property Hazard If the brake can be overpowered, the paver/finisher shall be taken out of service immediately and the brake units within the final drive planetary shall be rebuilt. Under no circumstances shall this paver/finisher be used before this brake malfunction is fully repaired. Failure to adhere to this admonishment may result in property damage, personal injury and even death. 4. With the THROTTLE Switch (32, Figure 5-27) in the IDLE position, move the Direction/Speed Control Lever (2, Figure 5-25) forward or reverse. The paver/ finisher should remain stationary, not being able to over power the brake. Figure 5-27


5-37

Section 5


QUARTERLY MAINTENANCE TASKS The following maintenance tasks shall be performed every quarter (3 months or 250 operational hours whichever occurs first). •

Engine Oil and Filter - Change

•

Air Cleaner - Check/Change

•

Short Coupled Drive Shaft - Grease

•

Fuel Pump - Check

•

Radiator Hoses - Check

•

Auger/Conveyor Drive Chains - Check/Adjust

•

Auger Sections - Inspect

•

Hopper Hinge Assembly - Inspect/Repair

Engine Oil and Filter - Change

!

WARNING

Toxic Hazard Some state and federal agencies have determined that used engine oil may be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion or prolonged contact with engine oil. If not reused, dispose of in accordance with local environmental regulations.

!

WARNING

Personal Injury Use care not to allow hot engine oil to come in contact with your skin. Failure to observe this warning could result in burns and subsequent infection could be possible. The engine oil and oil filter shall be changed every 250 operating hours or every 3 months, which ever occurs first. Perform this task in accordance with the procedure below. If more detailed information is required, refer to the Engine Operation and Maintenance Manual. 1. Position the vehicle on level terrain.

5-38



Section 5

2. Engage the parking brake. 3. If necessary, start the engine and allow it to run until the water temperature reaches 60° C (140° F). 4. Shut the engine down once the desired engine temperature is reached in the step above. 5. Locate a container with a capacity of at least 26 L (27 qts.). 6. Locate the drain plug (2, Figure 5-28) adjacent to the WASHDOWN hose as indicated by the placarded label (1, Figure 5-28). 7. Remove the drain plug (2, Figure 5-28) and allow the engine oil to start to drain. Figure 5-28

8. Remove the oil fill cap (1, Figure 5-29) from the engine. Figure 5-29

9. Clean the area around the oil filter head. 10. Remove the oil filter (1, Figure 5-30).


5-39

Section 5


!

CAUTION

Oil Leakage Make sure the o-ring did not remain on the filter head. Failure to remove this o-ring will result in an oil leak and possibly even engine damage if unattended for a period of time. 11. Clean the gasket surface of the filter head. 12. Obtain a new oil filter of the correct type. 13. Fill the new oil filter with lubricating oil. 14. Apply a light film of lubricating oil to the gasket seating surface.

!

CAUTION

Equipment Damage Use care not to over tighten the oil filter. Failure to observe this admonishment could result in a distortion of the threads or damage to the filter element seal. 15. Install the filter (1, Figure 5-30) as specified by the filter manufacturer. Figure 5-30

16. Clean the sealing surface of the oil drain plug.

5-40



Section 5

17. Inspect the oil drain plug threads and replace if there are visible signs of damage or excessive wear. 18. Install the drain plug. 19. Refer to Table 5-1 and choose an approved lubricating oil. Refer to the engine owners manual as required for climate considerations. 20. Fill the engine with clean lubricating oil to the proper level (approximately 9.5 L (10 qt.)) by adding oil through the engine fill opening. 21. Reinstall the engine oil fill cap (1, Figure 5-29). 22. Operate the engine and check for leaks at all filters and the oil drain plug.

Air Cleaner - Check/Change

!

CAUTION

Engine Damage Raw Unfiltered air can cause engine damage. Never service the air cleaner while the engine is running. Failure to comply with this Caution could result in engine damage in a very short period of time. This check shall be performed every 250 operating hours or every 3 months, whichever comes first. Perform the steps outlined below to inspect the air cleaner. If more detailed information is required, refer to the Engine Operation and Maintenance Manual.

!

WARNING

Personal Injury Hazard Use care when working around the engine, surfaces may be hot. Failure to comply with this admonishment could result in serious injury. 1. Shut the engine down.


5-41

Section 5


2. Loosen fastener (1, Figure 5-31) and remove the cover (2, Figure 5-31) from the engine air cleaner canister so the filter element can be removed and cleaned. Figure 5-31

3. Set the engine air cleaner canister cover (1, Figure 5-32) aside, exposing the air cleaner element (2, Figure 5-32). Figure 5-32

5-42



Section 5

4. Remove wing nut (1, Figure 5-33) that secures filter element inside of filter element canister. Figure 5-33

5. Gently remove the filter element (1, Figure 5-34) and set aside. Figure 5-34


5-43

Section 5


6. Clean the inside of the filter element canister (1, Figure 5-35). Figure 5-35

7. Clean the air cleaner either using the dry or wet method as follows:

!

WARNING

Personal injury. When using compressed air, ensure that appropriate protective clothing is worn to protect eyes and exposed parts of the body. Failure to adhere to this Warning could result in personal injury and even blindness.

!

CAUTION

Equipment Damage Air pressure should not exceed 6.89 bar (100 psi) from 3 cm (1/8 in.) diameter nozzle located 5 cm (2 in.) away from the filter element. Excessive air pressure can damage the air filter element and result in more serious engine damage after periods of operation with a damaged air filter element.

5-44



Section 5

a. To clean the air filter element using the dry method, perform the following: •

Carefully direct the compressed air, not to exceed 6.89 bar (100 psi) at an angle onto the inside surface of the air cleaner element.

•

Move the air jet up and down until no additional dust is being removed.

•

Visually inspect the filter element for damage and replace if necessary. a. To clean the air filter element using the wet method, perform the following:

!

WARNING

FIre Hazard Never use gasoline or solvents to clean the air filter element. These substances are flammable. Failure to adhere to this warning may result in fire or explosion and subsequent bodily injury or even death. •

Remove loose dirt from the filter element using a water hose.

•

Soak the filter element in a non-sudsing detergent solution for at least 15 minutes and not more than 24 hours.

•

Swish the filter element around in the solution to loosen dirt particles and put them into suspension in the solution.

•

Rinse the filter element from the “clean” side to the “dirty” side with a gentle stream of water. Rinse both sides if necessary.

•

Dry the filter element by circulating warm air (less than 71° C (160° F)). DO NOT use a light bulb to dry the filter element.

•

Visually inspect the filter element for damage and replace if necessary.

8. Replace the filter element (1, Figure 5-34) back into the canister (1, Figure 5-35) after it and the inside of the canister have been cleaned. 9. Secure the filter element in place inside the canister using the wing nut (1, Figure 5-33). 10. Replace the cover (1, Figure 5-32) on the canister, taking note of the top of the cover as indicated on the inside of the cover itself. 11. Secure the cover on the canister by tightening the fastener (1, Figure 5-31) on the cover.


5-45

Section 5


Short-Coupled Drive Shaft - Grease Apply approved lubricant (Table 5-1) to the short coupled drive shaft lubrication points (1, Figure 5-36) at the end of the first day of each quarter (250 hour operational period). Perform this task while the paver/finisher is still warm. Figure 5-36

Fuel Pump - Check Visually inspect the Fuel Pump mounting nuts, including the tail support bracket for loose or damaged hardware. This check must be performed every 250 operating hours or every 3 months, whichever comes first. If more detailed information is required, refer to the Engine Operation and Maintenance Manual. If damaged or loose hardware is noted during this inspection, contact equipment service personnel so that the necessary repairs can be made in a timely manner.

Radiator Hoses - Check Visually inspect the Radiator Hoses for cracks, cuts or signs of collapsing hoses. Make sure all hoses are securely clamped. This check must be performed every 250 operating hours or every 3 months, whichever comes first. If more detailed information is required, refer to the Engine Operation and Maintenance Manual. If damage is noted during this inspection, contact equipment service personnel so that the necessary repairs can be made in a timely manner.

5-46



Section 5

Auger/Conveyor Drive Chains - Check/Adjust

!

WARNING

Personal Injury Hazard Never touch augers or attempt to adjust drive chains while the engine is running. The augers could move catching and cutting parts of your body. Failure to observe this admonishment could result in serious injury. There should be approximately 6 mm (3/4 in.) free play in each Auger (left-hand (L.H.) and right-hand (R.H.)). This free play can be checked by manually rotating each auger. Proper adjustment of the auger/conveyor drive chains shall be maintained to insure sm ooth operation of the paver/finisher’s feed systems and to prevent damage to the drive components due to shock loads. The two auger/conveyor drive chains are totally enclosed in the center case (4, Figure 5-37). Adjustment of these chains is accomplished by moving the auger/conveyor drive transmissions (5, Figure 5-37) up or down. Figure 5-37

Perform the steps outlined below to adjust the auger/conveyor drive chains: 1. Loosen the mounting bolts (four on each drive transmission) (1, Figure 5-37). 2. Loosen each locknut (one on each drive transmission) (3, Figure 5-37). 3. Turn the adjusting bolts (one on each drive transmission) (2, Figure 5-37) in order to raise or lower the drive transmissions. 4. Check the free play in each auger and make additional adjustments of the adjusting bolts (2, Figure 5-37) until the required free play in each auger is achieved.


5-47

Section 5


5. Tighten each lock nut (3, Figure 5-37) after the required free play is achieved for each side of the auger. 6. Tighten each of the mounting bolts (four for each of the two drive transmissions) (1, Figure 5-37).

Hopper Hinge Assembly - Inspection/Repair The hopper hinge tubes (1 and 2, Figure 5-38) shall be replaced when the hinge no longer folds smoothly. If the tubes offset by more than 3 mm (1/8 in.) when raising the hopper wings, the hinges shall be replaced. Figure 5-38

Auger Section - Inspection and Replacement Auger Sections shall be inspected periodically f or excessive wear and signs of damage. The following procedure will provide some guidelines regarding this inspection. Cast auger segments are made of high-alloy steel to produce maximum wear life. They tend to wear the most along the outer edges and can continue to be used until they become smaller in diameter or break off. This result ing reduction in diameter limits the auger’s ability to deliver maximum material flow. Perform the steps outlined below to inspect the auger sections.

!

WARNING

Personal Injury Hazard Never stand near an auger section when the engine is ru nning. Make sure all personnel in the immediate area are aware of your presence near the auger. Never stand on an auger section. Failure to comply with this admonishment could result in serious injury or death.

5-48



Section 5

1. Position the paver/finisher on flat terrain. 2. Set the parking brake. 3. Shut the engine off. 4. Measure the outer diameter of each auger section. If a section has suffered more than a 25 mm (1 in.) loss of diameter, that section shall be replaced. 5. Visually inspect each of the auger sections for visible cracks or breakage. Replace any auger section that is broken or showing signs of cracking.

SEMI-ANNUAL MAINTENANCE TASKS The following maintenance tasks shall be performed on a semi-annual basis (every six months or every 500 operational hours). •

Hydraulic Filters and Fluid - Change

•

Engine Coolant - Check

Hydraulic Fluid and Filters - Change The hydraulic system shall be drained and all filters changed on a semi-annual basis (every 500 operational hours or every six months). This activity is broken down into the following tasks. •

Draining the hydraulic system

•

Changing hydraulic oil filters

•

Changing Hydraulic Tank Relief*

•

Changing Hydraulic System Charging Filter**

•

Refilling hydraulic system with fluid.

* The Hydraulic Tank relief shall be cleaned, inspected and if necessary changed every other time this task is performed. This is a task that shall be performed on an annual basis when the hydraulic tank is drained. ** The Hydraulic System Charging Filter should be replaced every other time this task is performed. Replacement of this filter is required on an annual basis.


5-49

Section 5


Draining the Hydraulic System

!

CAUTION

Disabled equipment Once the hydraulic system has been drained the vehicle is completely disabled until the system has been refilled and is back on line. Failure to give this detail your attention could result in unanticipated equipment downtime and potential loss of revenue.

NOTICE The hydraulic tank assembly is comprised of a pressurized (non-vented) tank and an unpressurized (vented) tank. The non-pressurized tank contains a check valve which prevents the pressurized oil from feeding back into it, but allows free-flow between the non-pressurized tank and the pressurized tank. When draining the hydraulic tank, it is recommended that you drain from the pressurized tank. The pressurized tank drain plug is located in the rear, bottom of the hydraulic tank and is accessible through a hole in the hopper floor. NOTE: For the sake of simplicity, locate a container of sufficient size to collect the volume of fluid that will be collected during the draining of the hydraulic system. The hydraulic tank hol ds 189 L (50 gal.) of fluid. Pumps also hold fluid. Drained fluid must be disposed of in a manner that is in compliance with local environmental regulations. Hydraulic fluid may be drained using either of two methods. The first method presented is through the manifold and fill cap of the tank, while the second method is through the tank lid and the fill cap.

5-50


MAINTENANCE INSTRUCTIONS Method One: Draining

Section 5

the hydraulic fluid through the manifold and fill cap.

1. Disconnect suction hose from general purpose pump or remove plug from suction manifold. Access to the plug is through an opening in the hopper floor (1, Figure 5-39). Figure 5-39

2. Remove hydraulic fill cap and dip stick assembly (1, Figure 5-40). Figure 5-40


5-51

Section 5


3. Drain non-vented (pressurized) tank through manifold (1, Figure 5-41) and hose to collection container. Figure 5-41

4. Wait until all fluid has been drained from pressurized side of the tank. 5. Insert hose from pump into vented (non-pressurized) tank. 6. Pump hydraulic fluid into collection container. Method two: Draining

the hydraulic fluid through the fill cap and the tank lid of the non-vented

(pressurized) tank. 1. Remove hydraulic tank fill cap and dipstick assembly (1, Figure 5-40). 2. Loosen tank lid (1, Figure 5-42) slightly (enough to all non-vented side of tank to begin to vent), but do not remove at this time. Figure 5-42

3. Insert hose from pump into opening on vented side of tank. 4. Pump all hydraulic fluid out of vented side of tank into collection container.

5-52



Section 5

5. Remove tank lid (1, Figure 5-42). 6. Remove hose from vented side of tank and reinsert it in the non-vented (pressurized) side of the tank. 7. Pump all hydraulic fluid out of the non-vented (pressurized) side of the tank into collection container.

Changing Hydraulic Oil Filters The following describes how to change the hydraulic oil filters. Before attempting to perform this procedure you must have completely drained all hydraulic fluid from the system as described in the previous procedure. 1. Clean the area around the hydraulic filters. 2. Remove each hydraulic filter (1 and 2, Figure 5-43) from the filter head assembly. Figure 5-43

!

CAUTION

Equipment Damage Be certain to remove any pieces of broken o-ring gasket left behind on the gasket surface of the filter head. Failure to adhere to this admonishment could result in hydraulic leaks, contamination and subsequent system degradation or damage to the system. 3. Clean the gasket surface of the filter head.


5-53

Section 5


4. Install one filter at a time as follows: a. Apply a light film of hydraulic fluid to the gasket seating surface of the new filter. b. Fill filter completely with hydraulic fluid.

!

CAUTION

Equipment Damage Do not over tighten the hydraulic oil filter. Failure to adhere to this admonishment could result in distorting threads or damage the filter element seal. Resulting in a system leak. c. Install the new filter as specified by the filter manufacturer. d. Repeat this process for each filter.

Removal and Cleaning of Relief (In Hydraulic Tank) The following describes how to remove and clean the relief valve located inside the hydraulic tank. There are no strainers in the hydraulic tank to clean. Internal tank maintenance is limit ed to the removal and cleaning of this relief. 1. Insure the cap (1, Figure 5-44) has been removed from hydraulic tank and the tank has been drained. Figure 5-44

5-54



Section 5

2. Remove the cap screws (1, Figure 5-45) from around the hydraulic tank lid (2, Figure 5-45). Figure 5-45

3. Remove the tank lid (2, Figure 5-45). 4. Visually locate the internal check valve and its fittings. 5. Loosen the fittings on each side of the check valve. 6. Lift the 5 psi check valve adapter with intergal relief out of the hydraulic tank.

!

WARNING

Fire, Personal Injury Mineral spirits are flammable. NEVER use mineral spirits while smoking or in an environment where open flame or sparks are present. Failure to adhere to this WARNING could result in a fire, and/or severe personal injury even death. 7. Clean the relief with mineral spirits and then blow it dry. 8. Inspect relief and replace if damaged, otherwise reuse the same relief during reassembly. 9. Reinsert the relief in the check valve adapter. 10. Reinstall the check valve adapter into the hydraulic tank and tighten the fitting on each side of the adapter. 11. Reinstall the hydraulic tank lid and tighten the cap bolts removed earlier.


5-55

Section 5


Changing Hydraulic System Charge Filter The following describes how to change the Hydraulic System Charge Filt er. It makes sense to perform this procedure when you are also draining the Hydraulic System during routine scheduled maintenance. Perform this procedure after you have completely drained all hydraulic fluid from the system as described in the previous procedure. 1. Disconnect and cap the hydraulic line leading (1, Figure 5-46) to the Hydraulic System Charge Filter Assembly (2, Figure 5-46). Figure 5-46

2. Remove charge filter. Take note of the direction the filter.

!

WARNING

Fire Hazard Mineral Spirits are flammable. Do not perform this procedure while near sparks, open flame or while smoking. Failure to adhere to this Warning could result in a fire and subsequent property damage, severe injury and/or even death. 3. Clean Charge Filter with mineral spirits and then blow-dry. 4. Inspect filter for signs of visible damage. If filter appears to be damaged, obtain a new filter and discard the damaged filter. 5. Install new or cleaned filter to filter head, taking care to insert it in the same direction it was in when removed. 6. Reconnect hydraulic line to Hydraulic System Charge Filter assembly.

5-56



Section 5

Refilling Hydraulic System with Fluid 1. Clean the area around the hydraulic tank. This will help prevent contamination of hydraulic fluid. 2. Reinstall tank lid (2, Figure 5-45) if removed. 3. Fill hydraulic tank with 189 L (50 gal.) of approved hydraulic fluid (Table 5-1). 4. Fill all hoses and pump cases with hydraulic fluid. 5. Start the engine and allow the hydraulic pumps to run for a short period of time. 6. Check the level of fluid in the hydraulic tank and add fluid as necessary to finish filling the system.

Engine Coolant - Check

!

CAUTION

Engine Damage DO NOT use an excessive amount of antifreeze or use a high silicate antifreeze in the cooling system. Over concentration of antifreeze or use of high silicate antifreeze can cause damage to the engine. This task shall be performed every 500 operating hours or every 6 months, whichever comes first. If more detailed information is required, refer to the Engine Operation and Maintenance Manual. If damage is noted during this inspection/maintenance task, contact equipment service personnel so that the necessary repairs can be made in a timely manner.

!

WARNING

Personal Injury Never remove a pressure cap from a hot engine. Wait until the engine has cooled to 50° C (120° F) or less before removing the pressure cap. Always remove the pressure cap slowly, allowing any steam to escape before fully removing the cap. Always wear safety glasses and gloves. Failure to observe this admonishment could result in serious burns to the face including your eyes resulting in possible blindness. PF-161 Paver/Finisher

5-57

Section 5


!

CAUTION

Equipment Damage Never use a sealing additive to stop leaks in the cooli ng system. This can result in plugging of the cooling system, which over time, will restrict system flow and compromise the system’s ability to cool the engine. Failure to observe this admonishment could result in overheating of the engine, eventual premature engine failure and could void you warranties. 1. Slowly remove the pressure cap from the radiator after the coolant in the radiator has cooled.

NOTICE Antifreeze is essential in every climate. It broadens the operating temperature by lowering the coolant freezing point and by raising it’s boiling point. It contains corrosion inhibitors that also protect the cooling system from corrosion and provide longer component life. 2. Check the antifreeze concentration in the radiator using a reliable, easy to read refractometer. Coolant should be at a level to protect the engine year-round to -25° C (-32° F). 3. If necessary add antifreeze, using a mixture of 50% water and 50% ethylene glycol or propylene glycol-based antifreeze.

ANNUAL MAINTENANCE TASKS The following maintenance tasks shall be performed on an annual basis (every year or every 1000 hours of operation whichever occurs first, always at the beginning of a paving season).

5-58

•

Front Bogie Wheels - Repack

•

Pump Drive Box - Change Fluid

•

Auger/Conveyor Planetaries - Change Fluid

•

Drive Wheel Planetaries - Change Fluid

•

Washdown Fuel Filter - Change

•

Engine Fuel Filter - Change



Section 5

Front Bogie Wheels - Repack The Front Bogie Wheels shall be repacked every 1000 operating hours or on an annual basis, whichever comes first. Repack the front bogie wheels (1, Figure 5-47) using approved grease (Table 5-1). Figure 5-47

Pump Drive Box - Change Fluid The Pump Drive Box fluid shall be changed every 1000 operating hours or on an annual basis, whichever comes first. Refer to Figure 5-48 and use only approved lubricants. Refer to Table 5-1 for a list of approved lubricants. Perform the following to change the fluid in the pump drive box. 1. After the vehicle is warmed up, park it on level terrain. 2. Obtain a container that is suitable to collect the fluid from the pump drive box (approximately 2.8 L (6 pints)).


5-59

Section 5


3. Remove the drain plug (1, Figure 5-48) and allow the fluid to drain into the container. Figure 5-48

4. Wait for all the fluid to drain. 5. Reinstall the drain plug (1, Figure 5-48). 6. Remove the fill plug (3, Figure 5-48) from the pump drive box. 7. Remove the level plug (2, Figure 5-48). 8. Fill the pump drive box with approximately 2.8 L (6 pints.) of approved lubricant. 9. Visually confirm the pump drive box is filled to a sufficient level by noting lubricant being up to the level plug opening. 10. Reinstall the level plug (2, Figure 5-48) and the fill plug (3, Figure 5-48).

5-60



Section 5

Auger/Conveyor Planetaries - Change Fluid The Auger/Conveyor Planetary fluid shall be changed every 1000 operating hours or on an annual basis, whichever comes first. Change the fluid in the auger planetaries (Figure 5-49) using approved fluid (Table 5-1) only. Perform the following when changing the fluid in the Auger/Conveyor planetaries: Figure 5-49

1. Park the vehicle on level terrain. 2. Remove the drain plug (3, Figure 5-49) and the fill plug (1, Figure 5-49). 3. Allow fluid to drain from planetary until finished. 4. Remove level plug (2, Figure 5-49). 5. Reinstall the drain plug (3, Figure 5-49). 6. Add approved lubricant through the fill plug (1, Figure 5-49). 7. Visually confirm that the appropriate amount of lubricant has been added to the planetary by observing that fluid level has risen to the level plug. 8. Reinstall the level plug and the fill plug (2 and 3, Figure 5-49).


5-61

Section 5


Drive Wheel Planetaries - Change Fluid The Drive Wheel Planetary fluid shall be changed every 10 00 operating hours or on an annual basis, whichever comes first. Change the fluid in the drive wheel planetaries using approved fluid (Table 5-1). Follow the guideline provided below when changing this fluid. 1. Allow oil in wheel ends to have reached operating temperature. 2. Position the paver/finisher on level ground with the oil drain plug (1, Figure 550) in the 6 o’clock position (4, Figure 5-50). Figure 5-50

!

WARNING

Personal Injury. Avoid contact with hot oil or components. Failure to comply with this Warning could result in personal injury, including severe burns.

NOTICE Do not allow oil to drain onto ground. Failure to adhere to this Notice may place you and your organization in direct violation of federal and local environmental regulations. 3. Place a container under the oil drain plug (1, Figure 5-50) and remove plug. 4. Allow oil to drain.

5-62



Section 5

5. Replace the oil drain plug. 6. Remove the Oil Fill (2, Figure 5-50) and Level (3, Figure 5-50) plugs from the wheel. 7. Add oil until oil is level with the bottom of the Level (3, Figure 5-50) plug hole. Refer to Table 5-1 for a list of approved lubricants. 8. Clean and replace Level (3, Figure 5-50) and Oil Fill (2, Figure 5-50) plugs and tighten. 9. Repeat procedure for other wheel end unit.

Engine Fuel Filter - Change The engine fuel filter (1, Figure 5-51) shall be changed every 500 operating hours or every 6 months, whichever comes first. There are two ty pes of fuel filters, either of which may be used on your engine. Only perform one of these procedures depending on how your engine is equipped. Determine which type of fuel filter you have on your engine and refer to the appropriate procedure below. If more detailed information is required, refer to the Engine Operation and Maintenance Manual. Figure 5-51

Changing a Canister - Type Fuel Filter

If your paver/finisher is equipped with a canister-type fuel filter, perform the following procedure. 1. Position the vehicle on level ground. 2. Shut the engine off.


5-63

Section 5


!

WARNING

Personal Injury, Explosion and Fire Hazard Flammable fluids will be present during the performance of this task. Do not smoke or allow any bystanders to smoke while you are performing any part of this procedure. Do not allow any activity to be performed that could result in the generation of an open spark. Failure to adhere to these guidelines could result in fire, explosion, personal injury and even death. 3. Locate the fuel filter. 4. Lift up on the filter drain lever and allow fuel to drain from the filter for approximately 5 seconds. 5. Clean all debris from around the canister lid. 6. Remove the filter lid and canister. If you cannot remove the lid by hand, you can use a crescent wrench. 7. Twist the canister and it will break away from the filter lid. The canister is incinerable. 8. Verify that the o-ring is also removed from the canister lid. If necessary, remove it and discard. 9. Insert a new filter element in the canister lid. 10. Lubricate the new o-ring that came with the filter element using clean engine oil.

!

CAUTION

Equipment Damage Use care not to over tighten the fuel filter. Failure to observe this admonishment could result in a distortion of the threads or damage to the filter element seal. 11. Replace the canister lid back on the canister body and hand-tighten by turning clockwise (CW). Use of a wrench to tighten the canister lid is not recommended.

5-64



Section 5

Changing a Spin-On-Type Fuel Filter

If your paver/finisher is equipped with a Spin-On-type fuel filter, perform the following procedure. 1. Position the vehicle on level ground. 2. Shut the engine off.

!

WARNING

Personal Injury, Explosion and Fire Hazard Flammable fluids will be present during the performance of this task. Do not smoke or allow any bystanders to smoke while you are performing any part of this procedure. Do not allow any activity to be performed that could result in the generation of an open spark. Failure to adhere to these guidelines could result in fire, explosion, personal injury and even death. 3. Locate the fuel filter.

NOTICE Be sure to drain the water/fuel into a container and dispose of in accordance with local environmental regulations. Do not drain onto the ground. 4. Use the filter drain valve to drain from the filter for approximately 5 seconds. 5. Clean the area around the fuel filter head. 6. Disconnect the water-in-fuel sensor connection from the wiring harness. 7. Remove the fuel filter by unbuckling the latch and unscrewing the filter. 8. Lubricate the filter o-ring with clean lubricating oil.

!

CAUTION

Equipment Damage Use care not to over tighten the fuel filter. Failure to observe this admonishment could result in a distortion of the threads or damage to the filter element seal.


5-65

Section 5


9. Install the fuel filter as specified by the filter manufacturer. 10. Reconnect the water-in-fuel sensor to the wiring harness.

Washdown Fuel Filter - Change Replace the WASHDOWN Fuel Filter (1, Figure 5-52) as follows: Figure 5-52

1. Clean the area around the Washdown Fuel Filter head. 2. Remove the Washdown Fuel Filter.

!

CAUTION

Fuel Leakage Make sure the o-ring did not remain on the filter head. Failure to remove this o-ring will result in an fuel leak and possibly cause a significant waste of fuel during the washdown process. 3. Clean the gasket surface of the filter head. 4. Obtain a new filter of the correct type. 5. Fill the new oil filter with diesel fuel. 6. Apply a light film of lubricating oil to the gasket seating surface.

5-66



Section 5

!

CAUTION

Equipment Damage Use care not to over tighten the filter. Failure to observe this admonishment could result in a distortion of the threads or damage to the filter element seal. 7. Install the filter as specified by the filter manufacturer.

MISCELLANEOUS MAINTENANCE TASKS The following maintenance tasks do not fall into any specific category and should be performed on an “as needed” basis. Read and become familiar with these tasks so that when it is necessary to perform one of them you know where the information is and basically what is involved. These miscellaneous maintenance tasks are: •

Adjustment to Hopper Wiper Bars

•

Adjustment of Swing Console

•

Adjustment of Steering Consoles and Seats

•

Adjustment of Hopper Side Extensions

•

Drive Tire Servicing and Hydroinflation


5-67

Section 5


Adjustment of Hopper Wiper Bars - As Required Hopper wiper bars (1, Figure 5-53) are provided to prevent paving material from accumulating in the area between the wing rear plates and the hopper bulkhead. Figure 5-53

The wiper bars should be adjusted to lightly contac t the bulkhead. A gap between the bulkhead and the wiper bars themselves should not exist, as this would allow material to accumulate and work through.

Adjustment of Swing Console - As Required The swing console height can be adjusted to any of three positions, by removing the four screws (1, Figure 5-54) and raising or lowering the console to a more comfortable operating level. Secure the console-height setting by re-installing the four screws (1, Figure 5-54). Figure 5-54

5-68



Section 5

Adjustment of Steering Consoles and Seats - As Required The steering consoles can be tilt adjusted to any one of three positions. Simply loosen the allen nut on the steering column (1, Figure 5-55) and reposition the steering wheel to a comfortable position. Then, retighten the allen nut. Figure 5-55

The operator’s seat can be adjusted fore and aft. Move the spring loaded lever (2, Figure 555) to the left, releasing the slide mechanism and position the seat to the desired position. The seat can also be height adjusted to accommodate the operator. To adjust the height of the seat, loosen the allen nut (3, F igure 5-55) and position the seat to the des ired height. Then tighten the allen nut, securing the seat to that height on the post.


5-69

Section 5


Adjustment of Hopper Side Extensions - As Required Hopper side-extension plates (1, Figure 5-56) are provided to help reduce material spillage from dump trucks. They can be repositioned as required to accommodate the average overhang length of the majority of dump trucks on your job. Figure 5-56

Drive Tire Servicing and Hydroinflation - As Required We recommend that this task be performed at a tire service store rather than in the field by equipment operators. Tire service stores are properly equipped and have trained personnel to perform needed services safely.

OFF SEASON STORAGE This procedure shall be followed at the end of a paving season or anytime the paver/finisher will be idle for an extended period. This is to protect the paver/finisher and ensure its availability when paving operations resume. 1. Clean the paver/finisher thoroughly, removing all paving material. Refer to the paragraph titled, “Cleanup and Washdown” presented earlier in this Section for detailed instructions pertaining to the proper method of cleaning the paver/ finisher. 2. Inspect the paver/finisher thoroughly for worn or damaged components and repair or replace, as required. 3. Fill the fuel tank with fuel.

5-70



Section 5

4. Drain the engine crankcase, change engine oil filter and refill engine crankcase with recommended lubricant. Refer to the Approved Lubricants Table 5-1 for a list of recommended products. 5. Replace the air filter. 6. Refer to the engine manual for further recommendations regarding off-season storage. 7. Disconnect the battery. If necessary to prevent freezing store the battery. Be sure to charge the battery before reinstalling. 8. Lubricate the entire paver/finisher as recommended in the lubrication and Service Schedule, Table 5-2. 9. Grease the bottom of the screed to prevent rusting and scaling.


5-71

Section 5

5-72



SECTION 6 - TROUBLESHOOTING


6-1

Section 6

TROUBLESHOOTING

TROUBLESHOOTING GENERAL This section contains general troubleshooting guidelines for the PF-161 Paver/Finisher. Troubleshooting for the paver/finisher in this m anual is limited to the correcting fluid levels and cleaning or changing filters. Additionally a brief table of pos sible trouble symptoms are included for the Blaw-Kontrol® Ultrasonic Grade Control System. Other malfunctions are considered beyond the scope of an operator level task and should be referred to your local maintenance/service organization or your nearest Ingersoll-Rand Distributor. The topics in this section are listed below. •

General Fault Isolation Tips/Information

•

Alarms Indications and Remedies

!

WARNING

Personal Injury Hazard When performing troubleshooting procedures it is critical to observe all safety precaution listed both in the body or these procedures and those listed in Section 1, SAFETY of this manual. Make yourself very familiar with the contents of Section 1 before attempting any of these procedures. Failure to observe this admonishment could result in serious injury, both disabling and lethal.

General Fault Isolation Tips/Information Improper operation and maintenance is the most frequent cause of machinery failures and problems. In the event of a failure it is recommended that you read through this manual. If you are unable to determine the cause of the problem, contact your local Ingersoll-Rand Distributor.

6-2


TROUBLESHOOTING

Section 6

How This Section Works

This section is laid out in two parts. First are general troubleshooting guidelines. These guidelines rev iew some basic rules that, if followed will increase your chances of successfully is olating a defective component, making a repair and returning the machine to service as quickly as possible. Third is a listing of alarms that may be displayed to alert the operator to a maintenance task that requires immediate attention. These tasks are typically the correcting of a fluid level or replacement of a dirty filter. Maintenance tasks to correct these conditions will also be referenced in this listing. General Troubleshooting Guidelines

The following are recommendations that if followed will result in shorter machine downtime and/or correct information being passed on to service personnel in the event of a failure beyond the scope of the operator. Always be aware of the status of the preventive maintenance on your machine. Keep these tasks current. It is unlikely a failure will occur if these tasks are performed at the recommended interval using the recommended material (lubricants and fluids). If a failure does occur, do not rely on your memory in terms of the exact symptoms. Always be aware of how your machine is performing. Symptom recognition is one of the most critical aspects of troubleshooting any mac hine. At a minimum take written note of the f ollowing when a failure occurs: •

General Failure Description - What happened?

•

Tasks Being Performed/Machine Status - What were you doing and what system(s) were operating on the paver/finisher at the time of the failure.

•

Miscellaneous - Were there any unusual sounds, smells or other symptoms (i.e., smoke, spark, smell of burning material, flickering control panel lights, etc.).

When a malfunction is noticed, address it immediately. If a malfunction is ignored, it could result in a cascading set of additional failures. A simple problem (low engine oil) if ignored could quickly turn into a serious machine failure causing lost equipment time and expensive repairs.


6-3

Section 6

TROUBLESHOOTING

Alarms Indications and Remedies The following alarm indications could be caused by an improper fluid level or dirty filter. If any of these conditions exist and the remedy listed does not correct the problem, get in touch with your service organization or local Ingersoll-Rand Distributor immediately. Refer to the Figure 6-1 for a photograph of these alarm indicators and refer to Table 6-1 for a list containing each indication and a recommended remedy.

Figure 6-1

Table 6-1: Malfunction Remedy Table SYMPTOM

6-4

CAUSE

REMEDY

Maintenance Indicator (5, Figure 6-1) is illuminated

Scheduled maintenance has not been performed

Review scheduled maintenance tasks and perform all tasks required to bring this machine up to date in terms of routine scheduled maintenance.

Water In Fuel Indicator (7, Figure 6-1) is illuminated

Water has been detected in the fuel system.

Refer to the Section 5 of this manual and drain the Water/Fuel separator. This task should be performed on a daily basis.

Check Engine Indicator (9, Figure 6-1) is illuminated

Problem with an engine fluid level or component.

Check instruments, make sure Oil Pressure gauge reads above 30 psi, Water Temperature gauge reads below 230° F, Oil Temperature gauge reads below 230° F and Battery Gauge reads above 10.5 Volts. If any gauge reads out of specification stated above refer to the specific symptom below. Otherwise contact your service organization as soon as possible.


TROUBLESHOOTING

SYMPTOM

Section 6

CAUSE

REMEDY

Hydraulic Filter Indicator (13, Figure 6-1) is illuminated

The hydraulic filter indicator will always illuminate when the machine is initially started and will remain illuminated until the hydraulic fluid heats up to normal operating temperature (approximately 10 minutes). If the indicator remains lit for more than 15 minutes the hydraulic system is restricted and maintenance is immediately required.

Possible Equipment Damage. When the hydraulic filter indicator (13, Figure 6-1) remains illuminated for extended periods (1 hour or more), replace the hydraulic filters. Failure to do so, could result in hydraulic system damage or degraded hydraulic system performance.

Oil Pressure Gauge reads less than 30 psi when the engine is operating at 2200 RPM

For some reason the engine is not developing adequate oil pressure.

Check that oil level is correct, refer to the Section 5 of this manual. Correct if necessary. Check that the oil filter was changed when last required. Correct if necessary. Refer condition to local service organization.

Water Temperature Gauge reads above 230° F

For some reason the engine is not being properly cooled.

Check performance of scheduled maintenance on the cooling system (Radiator). Look for coolant leaks, if leaks are discovered, refer problem to local service organization immediately. If necessary add engine coolant/water solution to radiator, refer to Section 5 of this manual. Turn problem over to local service organization if you cannot correct problem as stated above. Do not operate this machine until the problem is corrected.

Oil Temperature Gauge reads above 230° F

Battery Gauge is reading less than 10.5 volts.


For some reason lubricating oil is not keeping engine friction down to acceptable levels and internal temperatures are rising to dangerous levels.

Check level of lubricating oil as described in Section 5 of this manual.

For some reason the battery charge is not being maintained.

Refer problem to local maintenance organization.

Check to make sure all preventive maintenance has been performed. Refer problem to local service organization. Do not operate this machine until the problem is corrected.

6-5

Section 6

TROUBLESHOOTING

Blaw Kontrol ® Ultrasonic Grade Control System Troubleshooting Table 6-2 provides a list of various fault indications associated with the Blaw Kontrol Ultrasonic Grade Control System and a recommended remedy or set of remedies for each fault indication.

Table 6-2: Blaw-Kontrol ® Malfunction Remedy Table SYMPTOM No Display

CAUSE No power being supplied to the handset.

REMEDY Check: Paving Machine auto/manual switching. Paving Machine power supply Cable connections/damage to cables

Up/down arrows light, but there is no control to paver/finisher

No power being supplied to adjusting cylinder solenoids

Handset in manual mode. Paver/finisher in manual mode/ standby Check cables/connectors for continuity

6-6

Er1

Sonic sensor out of range

Raise or lower sonic sensor (adjusting cylinders)

Er2

Sonic sensor has no reference

Check/replace wire bail

Er4

Sensor abnormality

Remove and reconnect paver/ finisher power plug.

000

Sensor operation outside “Working Window”

Check “Working Window” settings Check mechanical integrity of sensor mountings Check for sensor field-of-view obstructions

SOS

Handset not communicating with sensor

Check cables and connections

Display shows erroneous segment characters or Both upper and lower displays show numbers

“Power-up” glitch

Reconnect main power connection

CAL flashes when selecting “auto”

Sensor not calibrated

Re-calibrate sensor


TROUBLESHOOTING

SYMPTOM

Section 6

CAUSE

REMEDY

Blaw-Kontrol is sluggish in operation (paver slow to react) Long elongated waves in material

Incorrect settings

Check sensitivity, pulse width, deadband and working window.

Adjusting cylinders appear slow in reaction Long elongated waves in material

Mechanical/Hydraulic settings

Check adjusting cylinder solenoids and restrictors

Blaw-Kontrol reacts too quickly

Incorrect settings

Check sensitivity and output pulse width

Movement in one direction only (Adjusting cylinder moves up only but not down or vise versa)

No power being supplied to one adjusting cylinder solenoids

Check wiring, cables and connectors

Paver has “jitter” partially evident when paver is paused (hunting)

Sensitivity too high

Lower sensitivity

Material shows signs of irregular ripples

Deadband too wide. Working window too small

Lower deadband Increase Working Window

“Doesn’t hold levels”

Incorrect setup

Read manual


6-7

Section 6

6-8

TROUBLESHOOTING


SECTION 7 - TECHNICAL SPECIFICATION


7-1

Section 7


TECHNICAL SPECIFICATION GENERAL This section contains the technical specification for the PF-161 Paver/Finisher. The following specification data is presented in this section. •

Machine Identification

•

Environmental Specifications

•

Physical Specifications

•

Miscellaneous Specifications

Machine Identification

Name of Machine

:

PF-161 Paver Finisher

Type of Machine

:

Paver/Finisher

Serial Number or Product Range

:

Production

Name and Address of Manufacturer

:

Ingersoll-Rand 312 Ingersoll Drive Shippensburg, Pennsylvania 17257-1295

Environmental Specifications This machine meets all federal EPA and OSHA requirements.

Physical Specifications

Dimension

7-2

Specification

Tractor Width (Hopper Sides Up)

2.5 m (98.5 in.)

Tractor Width (Hopper Sides Down)

3.22 m (125 in.)

Gage Width (center-to-center of drive wheels)

1994 mm (78.5 in.)

Wheelbase

1905 mm (75 in.)

Length (Overall with Wedge-Lock ® Screed)

5.24 m (17 ft., 2-3/8 in.)



Section 7

Dimension

Specification

Length (Overall with Omni Screed ® 1A)

5.39 m (17 ft., 8-3/8 in.)

Weight (Tractor Only)

9,775 kg (21,550 lbs.)

Weight (Total with Wedge-Lock ® Screed)

10,954 kg (24,150 lbs.)

Weight (Total with Omni Screed ® IA)

11,567 kg (25,500 lbs.)

Refer to Figure 7-1 for a diagram showing the overall dimensions of the paver/finisher. Figure 7-1


7-3

Section 7


Miscellaneous Specifications

Loading Ramp Angle

11°

Engine

Elite® Series, EPA certified, 4 cylinder, turbocharged diesel

Manufacturer

Cummins

Type/Model

4BTA 3.9

Displacement

3.92 L (239 cubic in.)

Horse Power

107 @ 2100 rpm

Cooling System Capacity

24.6 L (26 qts.)

Fuel System Capacity

144 L (38 gal.)

Electrical System

12 Volt-negative ground, with 105 Ampere alternator

Traction Drive

Independent, hydrostatic direct drive system.

Low Range @ 2100 rpm

0-59.7 m/min. (196 fpm)

High Range @ 2100 rpm

0-15.9 kph (9.9 mph)

Reverse

Full reverse in any of two speed ranges.

Traction Lock System

Provides full time tractive effort at both drive wheels

Paving Width

5.79 m (19 ft.)

Hydraulic System Capacity

151 L (40 gal.)

Brakes

Primary-hydrostatic drive, Secondary-hydraulic parking brakes (spring loaded)

Front Suspension

7-4

Wheels

Four steerable 305 mm (12 in.) wide x 559 mm (22 in.) dia. solid rubber tired wheels

Mounting

Offset tandem bogie frame

Weight distribution

Proportional split (40 - 60%) between the front and rear sets of bogies

Steering

Tie rod synchronized steering cylinders (one on each side) are mounted on the outside of the bogie frame



Rear Suspension

Pivot Steering

Section 7

Two 14:00 x 20 low pressure 182 to 260 kPa (25 to 35 psi), sand ribbed, high flotation tires, hydroinflated to 75%. Available for power assisted steering in tight quarters.

Front End

Either Oscillating Push Rollers or a Truck Hitch

Push Rollers

Two bearing equipped push rollers mounted on a 2502 mm (98.5 in.) wide oscillating frame.

Truck Hitch

Two bearing equipped push rollers mounted on an oscillating frame with electric/hydraulic actuated roller equipped clamp arms.

Maximum Arm Opening

3302 mm (130 in.)

Minimum Arm Opening

1829 mm (72 in.)

Degree of Swivel

±8 °

Drift from Center (right to left)

305 mm (12 in.) Automatically Self Centering

Hopper

8T (9.8 ton) 5.1m³ (181 ft.³) capacity

Truck Entry Width

3048 mm (120 in.)

Truck Dump Clearance (minimum)

565 mm (22.25 in.)

Power Flow Gates

Two separately operated, electrically controlled, adjustable flow gates.

Dual Feed System

Separate, infinitely variable speed, hydrostatic planetary drive for right and left side feed systems.

Conveyors

Two conveyors, R.H and L.H sides

Conveyor Tunnel Opening

1362 mm (53.625 in.)

Conveyor Floor Plate Thickness

10 mm (.375 in.)

Augers

Bolt on replaceable, high alloy, cast steel hemiscrew sections.

Auger Diameter

356 mm (14 in.)

Auger Flight Thickness

16 mm (5/8 in.)

Auger Height Adjustment (above grade)

114-279 mm (4.5-10.5 in.)

Auger Speed Maximum @ 2100 Engine rpm

122 rpm


7-5

Section 7

Automatic Feed Control System


Mat Kontrol ® II with a choice of either Paddle Sensors or Ultra 3 s® Sensors.

Mat Kontrol ® II with Paddle Sensors

Electric/hydraulic control arrangement that automatically controls both the “on-off” action and the infinitely variable operating speed of the dual feed system.

Mat Kontrol ® II with Ultra 3 s® Sensors

Same result as above, but utilizes a sounding system similar to a sonar to determine the amount of material present at the augers, then feedback controls manage the delivery of material.

Ventilation Control System

Machine mounted heat and fume extraction system.

Washdown System

Pressurized diesel fuel washdown system with a 10.7 m (35 ft.) hose.

Screed Options/Choices

7-6

Screed Heaters

One of the following screed heater options are on your machine

Diesel Only Heaters

Unitized, diesel fueled, SureFire ® burner/ blowers with manual activated spark igniter.

Diesel Heaters with ATIC

Unitized, diesel fueled, SureFire ® burner/ blowers with Automatic Temperature and Ignition Control (ATIC).

Propane Heaters with ATIC

Same as above but using propane as a fuel.

Wedge-Lock® Screed

Basic 8 ft. (2.44 m) fixed width vibratory screed with a one piece 623 mm (24.5 in.) wide x 13 mm (0.5 in.) thick, bolt-on replaceable screed plate.


1.8-2.4 m (6-8 ft.)


5.8 m (19 ft.)

Paving Depth Range

6-203 mm (0.25-8.0 in.), optional to 305 mm (12 in.)

Vibrator Speed

52 Hz (0-3100 rpm)

Center Crown

Mechanical dual crown kit provides simultaneous adjustment of center lead and tail crown from 76 mm (3 in.) positive to 19 mm (0.75 in.) negative.



Heat

Section 7

See screed heater data above.

Wedge-Lock Screed Extensions

Optional 152 mm (6 in.), 305 mm (12 in.), 610 mm (24 in.) and 914 mm (36 in.) extensions for the basic screed.

2.5/5B Hydraulic Screed Extensions

Optional hydraulic telescoping extensions.

Width Increase

Maximum 762 mm (2.5 ft.) each side while paving

Slope Control

Manual up to a maximum of 25 mm (1 in.) in 305 mm (12 in.) positive (at any extended width) or negative (fully extended)

Power Slope Option for 2.5/5B Hydraulic Extensions

On the go slope control for each extension relative to the main screed up to 25 mm (1 in.) in 305 mm (12 in.) positive (at any extended width) or negative (fully extended).

Berm Attachment Option for 2.5/5B Hydraulic Extensions

Replaces the standard screed plate arrangement to provide up to 102 mm (4 in.) of vertical rise in 610 mm (24 in.) at the outer end of each extension.

OmniScreed ® IA

Basic 8 ft. (2.44 m) power extendible, vibratory screed.


1.83-4.0 m (6-13 ft. 1-1/2 in.)

®

Maximum Paving Width (with optional Wedge-Lock ® extensions)

5.23 m (17 ft., 2 in.)

Paving Depth Range

6-203 mm (0.25-8 in.) optional to 305 mm (12 in.)

Vibrator Speed

42 Hz (0-2500 rpm)

Center Crown

Choice of either mechanical or hydraulic powered dual crown kits provides simultaneous adjustment of center lead and tail crown from 76 mm (3 in.) positive to 19 mm (0.75 in.) negative.

Extension Power Slope Range

Up to 25 mm (1 in.) in 305 mm 12-in. positive at any extended width (0 to 8%).

Heat

See screed heater data

AVAILABLE OPTIONS Front Wheel Power Assist


Provides up to 20% more tractive effort in the machines paving speed range

7-7

Section 7

7-8


Material Indicator Kit

Provides audible warning to the operator when material level drops below a preset threshold at the conveyor entry tunnel.

Blaw-Kontrol ® II

Automatically maintains the elevation and transverse (side-to-side) slope of a paver/ finisher’s screed to preset specification parameters, with respect to a single reference. Slope resolution is .005%.

UltraEye ® V Grade Sensor

Ultrasonic (non-contacting) grade sensor. Resolution is 0.508 mm (0.020 in.).

Automatic Level Control

Also known as a joint matcher. Resolution is 3.175 mm (.1259 in)

Floating Beam Reference

Eliminates need for stringline references. Available in 6.10, 9.14 and 12.20 m (20, 30 and 40 ft.) lengths and sets of two for dual grading purposes.

Mat Reference

Provides a 16.77 m (55 ft.) mobile grade referencing system.

55 Ft. (16.77 m) Mobile Referencing System

Combines the Floating Beam reference and Mat reference.

Additional Operators Umbrella

Second 1372 mm (54 in.) square operator’s umbrella.


SECTION 8 - FUEL AND LUBRICANT SPECIFICATIONS


8-1

Section 8


FUEL AND LUBRICANT SPECIFICATIONS GENERAL An extended warranty is available at no charge when you use genuine IR lubricants and parts. See your authorized IR dealer for details. Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the machine. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures. For maximum machine life and performance, we recommend the use of genuine IR brand lubricants. Different lubricants are needed and some components require more frequent lubrication than others. Therefore, it is important that the instructions regarding types of lubricants and the frequency of their application be explicitly followed. Lubrication tasks and suggested intervals are covered in Section 5 of this manual. Details concerning fuel, oil and other lubricants are provided in this section. A regular service program should be geared to the lubrication tasks covered in Section 5 of this manual. The suggested intervals are based on average operating conditions. In the event of extremely severe, dusty or wet operating conditions, more frequent lubrication than specified may be necessary. All oil levels are to be checked with the machine parked on a level surface and while the oil is cold, unless otherwise specified. On plug type check points, the oil levels are to be at the bottom edge of the check port. All grease fittings are SAE STANDARD unless otherwise indicated. Grease non-sealed fillings until grease is seen extruding from the fitting. Over lubrication on non-sealed fittings will not harm the fittings or components, but under lubrication will definitely lead to a shorter lifetime. Unless otherwise indicated, items not equipped with grease fittings (linkages, pins, levers, etc.) should be lubricated with oil once a week. Motor oil, applied sparingly, will provide the necessary lubrication and help prevent the formation of rust. An anti-seize compound may be used if rust has not formed. Otherwise, the component must be cleaned first. Grease fittings that are worn and will not hold the grease gun, or those that have a stuck check ball, must be replaced. To prevent minor irregularities from developing into serious conditions several other services or checks are recommended for the same intervals as the periodic lubrication. 1. Thoroughly wash all fittings, caps, plugs, etc. with non-flammable, non-toxic cleaning solution before servicing. This will prevent dirt from entering these components while lubricating. 2. Lubricants must be at operating temperature when draining.

8-2



Section 8

3. During regular lubrication service, visually check the entire unit in regard to capscrews, nuts and pins being properly secured. 4. Spot check several capscrews and nuts for proper torque. If any are found loose, correct the issue and make a more thorough investigation. 5. If a defect is detected that requires special maintenance service, stop the operation of the machine until the defect has been corrected. If necessary contact a local Ingersoll-Rand distributor for assistance. Periodic lubrication requirements are listed in the following Lubrication Chart. These requirements include lubricant checks and greasing designated areas of the machine.

FLUID CAPACITIES The following fluid capacities are provided for serv icing personnel who must perform machine maintenance in remote locations where complete shop facilities and resources are not available. These capacities will give the servicing personnel an approximation of the fluid capacities of the components being serviced. Always ensure that the specified method of check for adequate fluid levels is used.

Table 8-1: Fluid Capacities Fluid/Oil

Approximate Capacity

Diesel Oil

144 L (38 gal.)

Hydraulic Oil

189 L (50 gal.)

Engine Oil

9 L (10 qts.)

Engine Coolant

24.6 L (26 qts.)

HYDRAULIC OIL REQUIREMENTS AND SPECIFICATIONS The quality of the hydraulic oil is important to the satisfactory performance of any hydraulic system. The oil serves as the power transmission medium, system coolant and lubricant. Selection of the proper oil is essential to ensure proper system perform ance and life. Hydraulic oil used in this machine should meet the following criteria: •

ISO VG 46 with anti-wear additives

•

VI 140 (Min)


8-3

Section 8


LUBRICATING OIL/GREASE (EXCEPT ENGINE) I.

Extreme Pressure Gear Lubricant shall meet the following criteria: •

SAE 85W - 140W

•

API GL-5

•

MIL PRF 2105E

II. Extreme Pressure Multipurpose Grease shall meet the criteria of NLGI EP2. III. IR Synthetic Component Lubricant shall meet the following criteria: •

Synthetic Hydrocarbon with Phosphorus

•

ISO VG 220

•

VI 152

ENGINE LUBRICATING OIL SPECIFICATIONS NOTE: For latest applicable engineering lubricating oil specifications, contact engine manufacturer, distributor or your Ingersoll-Rand distributor. •

8-4

IR Multi-Purpose Premium Engine Oil - SAE 15W-40



Section 8

DIESEL FUEL SPECIFICATIONS Table 8-2: Diesel Fuel Specifications Viscosity (ASTM D-445)

1.3 to 5.8 centistrokes per second at 40° C (104° F)

Cetane Number (ASTM D-613)

40 minimum except in cold weather or in service with prolonged idle, a higher cetane number is desirable.

Sulfur Content (ASTM D-129 or 1552)

Not to exceed 1% by weight.

Water and Sediment (ASTM D-1796)

Not to exceed 0.1% by volume.

Carbon Residue (Ramsbottom ASTM D524 or Conradson, ASTM D-189)

Not to exceed 0.25% by weight on 10% volume residue

Flash Point (ASTM D-93)

At least 52° C (125° F) or legal temperature if higher than 52° C (125° F)

Density (ASTM D-287)

-1° C to 6° C (30° F to 42° F) API Gravity at 16° C (60° F) (0.816 to 0.876 Sp. Gr.)

Cloud Point (ASTM D-97)

6° C (10° F) below lowest ambient temperature at which the fuel is expected to operate.

Active Sulfur

Copper strip corrosion not to exceed No. 2 rating after 3 hours at 49° C (122° F)

Ash (ASTM D-482)

Not to exceed 0.02% by weight

Distillation (ASTM D-86)

The distillation curve must be smooth and continuous. At least 90% of the fuel must evaporate at less than 360° C (680° F). All of the fuel must evaporate at 385° C (725° F).


8-5

Section 8


HAZARDOUS SUBSTANCE PRECAUTION

!

WARNING

Hazardous Substance Precaution Obey the precautions listed on the following table. Failure to comply could result in serious injury, chronic health problems and even reproductive system damage. The following information is provided to assist the owners and operators of Ingersoll-Rand Machinery Equipment. Further information may be obtained by contacting your Ingersoll-Rand Road Machinery Equipment Distributor.

Table 8-3: Hazardous Substance Precaution SUBSTANCE Anti-Freeze

Avoid ingestion, skin contact and breathing fumes

Hydraulic Oil


Engine Lubrication Oil


Preservation Grease


Rust Preventative


Engine Fuel


Battery Electrolyte


SAE Gear Oil


Engine Exhaust Fumes

Avoid breathing and buildup of fumes in confined spaces

Electric Motor Dust (Brushes/Insulation)

8-6

PRECAUTION

Avoid breathing during maintenance


SECTION 9 - SCHEMATICS


9-1

SECTION 9

SCHEMATICS

General Information Additional full-size copies of the schematics are available by contacting the Ingersoll-Rand Road Development Division. See your authorized Ingersoll-Rand dealer for assistance, if required. For ultimate machine life and maximum performance, we recommend the use of genuine Ingersoll-Rand brand parts. The electrical and hydraulic schematics included herein that are applicable to the PF-161 Paver are listed below. Electrical Schematic •

Electrical schematic, Drawing No. 15632664, page 9- 3.

Hydraulic Schematic •

9-2

Hydraulic schematic, Drawing No. 15632672, page 9-4.


SCHEMATICS

SECTION 9

Electrical Schematic CONVERSION CHART 0 .00 1/16 .06 1/8 .13 3/16 .19 1/4 .25 5/16 .31 3/8 .38 7/16 .44 1/2 .50 9/16 .56 5/8 .63 11/16 .69 3/4 .75 13/16 .81 7/8 .88 15/16 .94 1 1.00

CHECK PRESSURE 2D SWITCH

FILTER -

-

POWER

s

TACH

58

60 AMP

-

s

OIL PRESS

VOLTS

-

s

s +

+

+

30 85

-

s

+ 87 86

+

OIL TEMP

WATER TEMP

40

RELAY

41 42 R E L A Y

8 8 6 7 8 5

3 0

S T A R T

01

01

01 R

J

01

1

B

2B

2B

2 STARTER

22

J

22

ALTERNATOR 2C

A

2C

B C

2D

D

R E P P O H

06A 10A

D E E R C S

E K A R B

R E G U A

BRAKE LIGHT

T R O E V E I T P S

START 15 AMP

*

*

*

*

01

10 MAIN

H C L I T T A R R W T A S E T O U S R N C I M

15 AMP ENGINE SHUT

06

33H

. C A R T . S O P

01

2B

A W F

*

E L T T O R H T

R O T A R B I V

N P W U O D

N P W U O D

N P W U O D

S N A R T

31

22

T F E L

T F I H S

O L

32

*

I H

50

48

N R O H

E T A G

K H C U C T R I T H

15

E T A G

W O H L L F

W O H L R F

N A M

O T U A

*

P U

T H G I R

N P W U O D

N A M

O T U A

F G

LH AUGER CONV.

AUGER

AUGER

LH

RH

H

J

N W O D

K M

07

167L 167R

37

21 39

20 170A

2C

A

38

12

DOWN

11 02A

B

36

2D

C

5

23

15 AMP

E 13

D

2E

24

01

09

E 27

F G

168 01

N N I W W N O H L O P O P W I E D U D U O P / L R R H D D D U T O T E R E E E R R R T A P P E E E E O O R R B P P R R G G T O O C C U U O H I T V H H S S A A M

20 15 AMP 02B

E V I T I S O P

N O I T C A R T

H

F F O / N O

E K A R B

A W F

N A F . S . R . F

RH AUGER CONV.

N I

T U O

02C

15 AMP

A L 0 3 7 3 1

02D

H 3 3

7 3

0 5

6 3 9

9

9 3

9

8 3

8 2

5 1

6 1

4 2

5 2

6 2

2E

15 AMP 22

7 8

IN MOTION

85

87A 86

B RH SENSOR G PLUG R W

33L

87 30

B LH SENSOR G PLUG R W

0 5 3 8

MATERIAL LOW

15 AMP

6 8

30 86

87 85

7 8 MERCURY SWITCHES

6 8

LH FLOWGATE

15 AMP

RH FLOWGATE

87

0 5 3 8

87A 86

30

87

30

86

85

87

30

85

50 MICRO SWITCH ON CONTROL HANDLE

ON FLOWGATES 87 87A 86 FUEL

15 AMP

87 85

86

BLACK SIGNAL COND.

BLACK SIGNAL COND.

GREEN

GREEN

RED

RED

WHITE

WHITE

85 26

26A 30 86

30 85

PUMP

25 AMP 08

ES15632664_0101


9-3

SECTION 9

SCHEMATICS

Hydraulic Schematic

350 PSI

A

A

5075 PSI

4.92 CI/REV 1.04 CI/REV

1.03 CI/ REV

1.71 CI/REV

5075 PSI

2.9 CI/REV 2.4 CI/REV

350 PSI

B

1/16 ø

36.6 CI/REV

GB

B

ø 9 3 0 .

5.5 1/16 ø B

I 0 S 0 8 P

350 PSI 4.92 CI/REV 1.04 CI/REV

COOLER

T

.09375 ø

2.4 CI/REV

S

2.9 CI/REV

100

FRONT WHEEL ASSIST S 100

350 PSI

P

5075 PSI

5.5 GPM

30 PSI

N I

CASE FLUSHING PROVIDED BY DIFFERENTIAL PRESSURE BETWEEN PRESSURIZED (5 PSI) AND NON-PRESSURIZED SIDES OF HYDRAULIC TANK.

I S P 5

PLANTETARY 53.3:1 189 PSI BRAKE RELEASE A

5075 PSI

SCREED LIFT CYLINDER

P

COOLER BYPASS

1.71 CI/REV

SCREED EXTENSION CYLINDERS

I S P 0 0 8 1 0 0 2 1

HAND PUMP

A

36.6 CI/REV

BRAKE

ø 9 3 0 .

F

SCREED LIFT CYLINDER

00112-772-00

PLANETARY 53.3 :1 189 PSI BRAKE RELEASE

T U O

T SCREED VALVE

.37 IN /REV P T V

FUME RECOVERY SYSTEM

1.03 CI/ REV

D E E R C S

AUGER/CONVEYOR CIRCUIT

TRACTION CIRCUIT

B

T V

F 5.5 F

VIBRATOR

25

HYDRAULIC

MOTORS

AUX1

1800 PSI

CASE FLUSHING PROVIDED

AUX2

X

THROTTLE LO

MOTOR HI

THROTTLE HI

.024ø

.024 ø

.5 GPM

6 GPM

BY DIFFERENTIAL PRESSURE

SCREED I S P 0 5

BETWEEN PRESSURIZED (5 PSI)

8

AND NON-PRESSURIZED SIDES OF HYDRAULIC TANK.

CONVERSION CHART 0 .00 1/16 .06 1/8 .13 3/16 .19 1/4 .25 5/16 .31 3/8 .38 7/16 .44 1/2 .50 9/16 .56 5/8 .63 11/16 .69 3/4 .75 13/16 .81 7/8 .88 15/16 .94 1 1.00

9-4

2.9 CI/REV

BLAW KONTROL 6 GPM S 100

PG X STEER

VIBRATOR

HOPPER UP

X HOPPER DOWN

TANK

SCREED LIFT

AUGER DOWN

AUGER UP

CHARGE PRESSURE

TRUCK HITCH (OPTIONAL)

X CG

THROTTLE

AUGER LIFT

MAIN VALVE 'P'

'R'

'P' 'T'

'L'

'T'

HOPPER 'L'

'R'

GENERAL HYDRAULIC CIRCUIT STEERING CIRCUIT

PRESSURIZED

NON-PRESSURIZED

HYDRAULIC RESERVOIR TYPES

HYD15632672_0001


SECTION 10 - RECOMMENDED SERVICE PARTS

10-1

PF-161

SECTION 10 - RECOMMENDED SERVICE

Recommended Service Parts

Assembly

Description

1000 Hrs

2000 Hrs

3000 Hrs

CPN

1

15624828

Push Rollers Push Roller Roller

2

21057864

Shaft

2

20962239

Bearing

4

20930848

Hopper Corner Overflow Guard

1

21141585

Center Overflow Guard

1

21141577

Hinge Tube

1

20233979

Hinge Rod

1

Hopper/Screed Lift Cylinder

20290722 1

20304218

Flow Gates RH Flow Gate Plate

1

21141528

LH Flow Gate Plate

1

21141502

Jack (Power Flow Gate Assembly)

1

20946851

Conveyor Chain Assembly

2

20938908

Conveyor Chain Connecting Pin

2

20938916

Conveyor Chain Cotter Pin

2

20938924

Drag Bar

2

20349759

Conveyor Chain Repair Kit

2

20939229

Conveyor

Idler Shaft

1

21140850

Bearing

1

21443767

LH Front Chain Guard

1

21140900

RH Front Chain Guard

1

21140918

LH Rear Chain Guard

1

21140777

RH Rear Chain Guard

1

21140785

LH Rear Floor Plate

1

21140736

RH Rear Floor Plate

1

21140744

Center Floor Plate

1

21140751

Front Floor Plate

1

21140769

1

15502842

Auger / Conveyor Drive Roller Chain Outer Conveyor Bearing

1

20931747

Inner Conveyor Bearing

1

20292165

1

21140975 21140975

Auger Drive Sprocket Sprocket

10-2



Assembly

Description

PF-161

1000 Hrs

2000 Hrs

3000 Hrs

CPN

Conveyor Drive Sprocket

1

21058888

Sprocket

1

21140975

Housing Auger/Conveyor Drive Drive Pump Auger/Conveyor Drive Drive Pump Filter Filter

1

1

15622681

1

20292330

1

20926036

Auger/Conveyor Planetary Planetary Drive Drive

1

20924262

Auger/Conveyor Drive Drive Motor (Eff. (Eff. With S/N S/N 16128-01)

1

20928982

Auger/Conveyor Drive Drive Motor (Prior to to 16128-01)

1

20929857

Auger LH Kick-in Auger Section

1

20955274

RH Kick-in Auger Section

1

20955282

LH Long Auger Section

1

20954988

RH Long Auger Section

1

20955001

LH Short Auger Section

1

20954996

RH Short Auger Section

1

20955019

LH Kick-out Auger Section

1

20206421

RH Kick-out Auger Section

1

20206439

LH Auger Section, Extension

1

20954988

RH Auger Section, Extension

1

20955001

Outer Auger Extension Support Bearing

1

20292157

Inner Auger Bearing

1

20292165

Feed Control Paddle

1

21079926

Wire

1

20308193

Plug

1

20933560

Insulated Terminal

1

20940789

Traction Drive Pump

1

15497035

Traction Drive Motor (Eff. With S/N 1613001)

1

20329892

Traction Drive Motor (Eff. S/N 16126-01 to 16130-01)

1

20304804

Traction Drive Motor (Prior to S/N 1612601)

1

20930103

Traction Drive Planetary (Eff. With S/N 16130-01)

1

20327243

Traction Traction Drive Planetary (Eff. S/N 16126-01 to 16130-01)

1

13784087

Traction Drive


10-3

PF-161

Assembly


Description

1000 Hrs

2000 Hrs

Traction Drive Planetary (Prior to S/N 16126-01)

3000 Hrs

CPN

1

20924312

1

20942629

1

20986360

1

20930996

Bogie Steering Solid Tire

1

1

Wheel Bearing Assembly

1

1

Bearing Cup

1

20930327

Bearing Cone

1

20930715

Tie Rod

1

21140637

Engine John Deere 4039T Diesel Oil Filter Element

2

2

2

20937710

Fuel Filter Element

2

2

2

20937728

1

1

1

20937884

1

20300794

1

20359659

1

13547989

Air Filter Element Element Fan/Alternator Belt Matched Set Alternator Starter Radiator Cap

1

1

1

20937777

1

1

1

20937884

Oil Filter Element

2

2

2

20289153

Fuel Filter Element

2

2

2

20289161

1

20289179

1

13788013

1

13788021

Air Cleaner Element Element John Deere 4045T Diesel

Fan/Alternator Belt Matched Set Alternator Starter Radiator Cap

1

1

1

20937777

1

1

1

20937884

Oil Filter Element

2

2

2

21439419

Primary Fuel Element

2

2

2

21439385

Secondary Fuel Element

2

2

2

21439393

1

21439401

1

13787908

1

20937793

Air Cleaner Element Element Cummins 4BTA (Prior to S/N 16115-10)

Fan/Alternator Belt Matched Set Alternator Starter Air Cleaner Element Element

1

1

1

20937884

1

1

1

20937777

Strainer Fuel Filter

2

2

2

21443825

Primary Fuel Filter

2

2

2

20163150

Radiator Cap Cummins 4BTA (Eff. S/N 16115-10)

10-4



Assembly

Description Oil Filter

PF-161

1000 Hrs 2

2000 Hrs

3000 Hrs

CPN

2

2

21439419

1

20259099

1

13787908

1

13366620

Fan/Alternator Belt Matched Set Alternator Starter Radiator Cap

1

1

1

20937777

Hydraulic Tank Filter Element

1

1

1

20925756

Hydraulic Filter Lip Gasket

1

1

1

20925806

General Purpose Pump

1

20928842

Main Control Valve

1

20929253

Power Steering Unit (Eff. With S/N 1610501)

1

20930160

Power Steering Unit (Prior to S/N 1610501)

1

20925061

Steering Cylinder

1

20926739

Auger Lift Cylinder Cylinder

1

20929675

Throttle Cylinder (Eff. With S/N 16104-01)

1

20929030

Throttle Cylinder (Prior to S/N 16104-01)

1

20929741

Brake/Release and Shift Valve (Eff. With S/ N 16130-01)

1

20329884

Brake/Release and Shift Valve (Prior to S/N 16130-01)

1

20177606

Side Arm Cylinder

1

20924742

Pump Control Fluid Filter

1

20929535

Hydraulics

Electrical Circuit Breaker, 30 Amp

1

1

1

20190682

Circuit Breaker, 20 Amp

1

1

1

20933503

Relay

1

1

1

20934592

Relay

1

1

1

20161055

1

20933974

1

20928149

1

20191003

Back Cushion Cover

1

20190997

Switch, 3 Position, 6 Terminal

1

20934195

Limit Switch

2

20934212

Switch, 3 Position, 3 Terminal

2

20934501

Actuator for for CPN 20934212 Switch Switch

Operator Platform Screed Heater & Washdown System Filter

1

1

Arm Rest Cover/Bottom Cover/Bottom Cushion Cushion Cover

Kits PF-161 Decal Kit Hopper/Screed Lift Cylinder Seal Kit


1

TBD 1

20924494

10-5

PF-161

Assembly


3000 Hrs

CPN

Traction Drive Motor Seal Kit

1

59019679

Traction Drive Planetary Seal Kit (Eff. S/N 16130-01)

1

20311122

Traction Drive Planetary Seal Kit (Eff. S/N 16128-06 to 16130-01)

1

13784020

Traction Drive Planetary Seal Kit (Prior to S/ N 16128-06)

1

20924338

General Purpose Pump Repair Kit

1

20925608

Auger/Conveyor Drive Pump Seal Kit

1

20926127

Auger/Conveyor Drive Motor Seal Kit

1

20926218

Auger/Conveyor Planetary Drive Gear Kit

1

20924288

Vibrator Motor Repair Kit

1

20926390

Throttle Cylinder Seal Kit

1

20176608

Power Steering Unit Seal Kit (Eff. With S/N 16105-01)

1

20376349

Power Steering Unit Seal Kit (Prior to S/N 16105-01)

1

20195327

Side Arm Cylinder Seal Kit

1

15493612

Steering, Auger Lift Cylinder Seal Kit

2

20924494

Journal & Bearing Repair Kit

1

20960373

Description

1000 Hrs

2000 Hrs

Optional Equipment Truck Hitch Assembly Push Roller

2

21057864

Bearing

2

20930848

Shaft

2

20962239

Side Roller Assembly

2

20217782

Side Roller

2

20262655

Side Roller Shaft

2

20218004

Truck Hitch Cylinder

1

20174561

Truck Hitch Cylinder Seal Kit

1

20926952

Pivot Pin

1

20262663

Pivot Pin Bearing

1

20931036

Offset Arm

1

20218251

Truck Hitch Control Valve

1

20176848

Jack Assembly

1

20986006

Jack Repair Kit

1

20946752

Side Arm Guide Roller

1

21062559

LH Automatic Level Control Valve

1

15580996

RH Automatic Level Control Valve

1

15581002

Automatic Level Control Assembly/Tow Point Control

10-6



Assembly

PF-161

1000 Hrs

Description

2000 Hrs

Side Arm Cylinder

3000 Hrs

CPN

1

20924742

Electric Flow Gate Actuator

1

20946851

RH Flow Gate Plate

1

15584477

LH Flow Gate Plate

1

15584436

Front Wheel Assist Valve

1

20929956

Front Wheel Assist Motor

1

20929758

Seal Kit

1

20929766

Front Wheel Assist

LUBRICANTS 1 Qt.

1 Gal.

5 Gal.

55 Gal.

IR All-Season Premium Hydraulic Oil

n/a

n/a

59045179

59045187

IR Multi-Purpose Premium Engine Oil

59022343

59023507

57022327

59022335

IR Premium Limited-Slip Component Lubricant

13248455

13248463

59022418

59022426

IR Premium Multi-Purpose ATF

13248471

13248489

59023572

59023580

IR Synthetic Component Lubricant

13248430

13248448

59877597

59022459

IR Synthetic Plus Component Lubricant

13248414

13248422

59046177

59046165


10-7

10-8


WORD INDEX NUMERIC 3-Position Function Toggle Switch ...................................................................................................................... 3-14 -A Additional Operator’s Umbr ella Option .................................................................................................................. 17 Adjustment of Hopper Side Ext ensions - As Required ....................................................................................... 5-70 Adjustment of Hopper Wiper Bars - As Required ............................................................................................... 5-68 Adjustment of Steering Consoles and Seats - As Required ...............................................................................5-69 Adjustment of Swing Console - As Required ...................................................................................................... 5-68 Air Cleaner - Check/Change ............................................................................................................................... 5-41 Alarms Indications and Remedies ........................................................................................................................ 6-4 Alternate Ramp Method ........................................................................................................................................ 1-6 Annual Lubrication and Service .......................................................................................................................... 5-17 Annual Maintenance Requirements .................................................................................................................... 5-17 ANNUAL MAINTENANCE TASKS .....................................................................................................................5-58 Approved Lubricants ........................................................................................................................................... 5-14 ASSEMBLY ........................................................................................................................................................... 2-2 Auger Bearings - Grease .................................................................................................................................... 5-21 Auger Control Switch ............................................................................................................................................ 3-8 Auger Extension Switch ............................................................................................................................. 3-18 3-20 Auger Override Toggle Switch ................................................................................................................... 3-18 3-20 Auger Section - Inspection and R eplacement .....................................................................................................5-48 Auger Specifications ................................................................................................................................................ 9 Auger Speed Control Knob ........................................................................................................................ 3-18 3-20 Auger/Conveyor Drive Chains - Check/Adjust .................................................................................................... 5-47 Auger/Conveyor Planetaries - Change Fluid ...................................................................................................... 5-61 AUGERS .................................................................................................................................................................. 9 AUTOMATIC FEED CONTROL S YSTEM ............................................................................................................. 10 Automatic Level Control ......................................................................................................................................... 17 ,

,

,

-BBattery Gauge ....................................................................................................................................................... 3-6 BE AWARE OF SAFETY INFORMATION ............................................................................................................ 1-2 Before you Begin .................................................................................................................................................. 2-2 BERM ATTACHMENT OPTION ............................................................................................................................ 15 Blaw Kontrol® Ultrasonic Grade Control System Troubleshooting .......................................................................6-6 Blaw-Kontrol® Malfunction Remedy Table ...........................................................................................................6-6 Blaw-Kontroll® II Option ......................................................................................................................................... 16 Brake Engaged Indicator ...................................................................................................................................... 3-5 Brake Release Hand Pump ................................................................................................................................ 3-12 Brake Release Hand Valve ................................................................................................................................. 3-11 BRAKES .................................................................................................................................................................. 6 -CChanging a Canister - Type Fuel Filter ...............................................................................................................5-63 Changing a Spin-On-Type Fuel Filter ................................................................................................................. 5-65 Changing Hydraulic Oil Filters ............................................................................................................................ 5-53 Changing Hydraulic System Charge Filter .......................................................................................................... 5-56 Check Engine Indicator ......................................................................................................................................... 3-5 CLEAN UP AND WASHDOWN ............................................................................................................................ 5-6 CONTROLS ........................................................................................................................................................... 11 Conveyor Chains - Inspect/Adjust ....................................................................................................................... 5-29 CONVEYORS .......................................................................................................................................................... 9 Cooling Fan - Inspect .......................................................................................................................................... 5-26 COOLING SYSTEM ................................................................................................................................................. 6 Crankcase Breather Tube - Inspect .................................................................................................................... 5-28 PF-161 Paver/Finisher

W-1

WORD INDEX -DDaily Lubrication and Service ............................................................................................................................. 5-15 Daily Maintenance Requirements ....................................................................................................................... 5-15 Daily Maintenance Tasks .................................................................................................................................... 5-19 DIESEL FUEL SPECIFICATIONS ........................................................................................................................ 8-5 DIESEL HEATERS WITH AUTOMATIC TEMPERATURE .................................................................................... 13 DIESEL ONLY HEATERS ..................................................................................................................................... 12 DIRECTION-SPEED CONTROL LEVERS ...........................................................................................................3-2 Draining the Hydraulic System ............................................................................................................................ 5-50 Drive Belts - Inspect ............................................................................................................................................ 5-28 Drive Tire Servicing and Hydroinflation - As Required ........................................................................................ 5-70 Drive Wheel Planetaries - Change fluid .............................................................................................................. 5-62 DUAL FEED SYSTEMS ........................................................................................................................................... 8 -EELECTRICAL SCHEMATIC................................................................................................................................... 9-3 ELECTRICAL SYSTEM ........................................................................................................................................... 5 Empty Tunnel Indicator ......................................................................................................................................... 3-5 ENGINE ................................................................................................................................................................... 5 Engine Air Intake Piping - Inspect ....................................................................................................................... 5-27 Engine Coolant - Check ...................................................................................................................................... 5-57 Engine Fuel Filter - Change ................................................................................................................................ 5-63 Engine Kill Button .................................................................................................................................................. 3-7 ENGINE LUBRICATING OIL SPECIFICATIONS .................................................................................................8-4 Engine Oil - Check Level .................................................................................................................................... 5-23 Engine Oil and Filter - Change ............................................................................................................................ 5-38 Engine Radiator - Check Level ........................................................................................................................... 5-24 Engine Tachometer/Hour Meter ............................................................................................................................ 3-3 Environmental Specifications ................................................................................................................................ 7-2 Extension Fuel Pump Switch ..................................................................................................................... 3-18 3-19 Extension Heater Igniter Switch ................................................................................................................. 3-18 3-20 Extension Slope Toggle Switch ................................................................................................................. 3-17 3-20 ,

,

,

-FFloating Beam Reference Option ........................................................................................................................... 17 Flow Gate Position Indicators ............................................................................................................................. 3-13 FLUID CAPACITIES ............................................................................................................................................. 8-3 Front Bogie Wheels - Repack ............................................................................................................................. 5-59 Front Conveyor Bearing - Grease ....................................................................................................................... 5-20 FRONT SUSPENSION ............................................................................................................................................ 7 Front Wheel Assist Switch .................................................................................................................................... 3-6 Front Wheel Bogie Pivot Bearings - Grease .......................................................................................................5-35 Front Wheel King Pins - Grease ......................................................................................................................... 5-34 Front Wheel Power Assist Option .......................................................................................................................... 16 FUEL AND LUBRICANT SPECIFICATIONS ........................................................................................................ 8-2 Fuel Pump - Check ............................................................................................................................................. 5-46 Fuel Pump Switch ............................................................................................................................................... 3-20 FUEL SYSTEM ........................................................................................................................................................ 6 Fuel Water Separator - Drain .............................................................................................................................. 5-28

W-2


WORD INDEX -GGENERAL ................................................................................................................. 1-3 2-2 4-2 5-2 6-2 7-2 8-2 GENERAL ASSEMBLY ........................................................................................................................................ 2-2 GENERAL EQUIPMENT OPTIONS ...................................................................................................................... 16 General Fault Isolation Tips/Information ...............................................................................................................6-2 GENERAL INFORMATION ...................................................................................................................................... 4 General Troubleshooting Guidelines .................................................................................................................... 6-3 Governor Switch ................................................................................................................................................. 3-10 ,

,

,

,

,

,

-HHAZARDOUS SUBSTANCE PRECAUTION ............................................................................................... 1-12 8-6 Hopper Control Switch .......................................................................................................................................... 3-9 Hopper Hinge Assembly - Inspection/Repair ...................................................................................................... 5-48 Horn Button ........................................................................................................................................................... 3-9 How This Section Works ....................................................................................................................................... 6-3 Hydraulic Filter Light ............................................................................................................................................. 3-6 Hydraulic Fluid - Check Level ............................................................................................................................. 5-21 Hydraulic Fluid and Filters - Change ................................................................................................................... 5-49 HYDRAULIC OIL REQUIREMENTS AND SPECIFICATIONS .............................................................................8-3 HYDRAULIC SCHEMATIC .................................................................................................................................... 9-4 HYDRAULIC SCREED EXTENSIONS .................................................................................................................. 14 HYDRAULIC SYSTEM ............................................................................................................................................ 6 ,

-IIDENTIFICATION DATA .......................................................................................................................................... 3 IDENTIFICATION OF MAJOR COMPONENTS .................................................................................................... 18 IGNITION CONTROL (ATIC) ................................................................................................................................. 13 Initial Screed Angle-of-Attack ................................................................................................................................ 4-5 Initial Screed Elevation ......................................................................................................................................... 4-4 Installation of 1-foot Bolt-on Screed Extension ...................................................................................................2-21 Installation of Additional Augers .......................................................................................................................... 2-15 Installation of the 18-inch Tapered-Joint Extension ............................................................................................ 2-24 Installation of the 8-foot Wedge-lock Screed ...................................................................................................... 2-26 Installation of the Ags (7.5) Controllers ...............................................................................................................2-31 Installation of the Automatic Feed Control Sensors ............................................................................................ 2-10 Installation of the Cut-off Plate ............................................................................................................................ 2-14 Installation of the Edger-plate Assemblies ............................................................................................................ 2-8 Installation of the Paddle Sensors ...................................................................................................................... 2-10 Installation of the Steering Guide .......................................................................................................................... 2-7 Installation of Ultra 3s Ultra Sonic Sensors .........................................................................................................2-12 Installation of Ultrasonic 4 Sonic Averaging System/Sonic Joint Matcher .......................................................... 2-28 INTRODUCTION ..................................................................................................................................................... 2 -JJog Toggle Switch ............................................................................................................................................... 3-14


W-3

WORD INDEX -LLCD ..................................................................................................................................................................... 3-16 LH and RH Flow Gate Control Toggle Switches .................................................................................................3-17 LH Control Panel ................................................................................................................................................. 3-17 LH Flowgate Control Switch .................................................................................................................................. 3-8 Lighting the Screed Heater ................................................................................................................................... 4-5 LOADING AND UNLOADING ............................................................................................................................... 1-6 Loading Dock with Ramp (Preferred Method) .......................................................................................................1-6 Lubricants ........................................................................................................................................................... 5-13 LUBRICATING OIL/GREASE (EXCEPT ENGINE) ..............................................................................................8-4 LUBRICATION AND SERVICE SCHEDULE ...................................................................................................... 5-14 -MMACHINE DESCRIPTION ....................................................................................................................................... 4 MACHINE IDENTIFICATION ................................................................................................................................... 3 Machine Identification ........................................................................................................................................... 7-2 Machine Identification Data ...................................................................................................................................... 3 MAIN CONTROL PANEL ...................................................................................................................................... 3-3 Main Fuel Pump Power Switch .................................................................................................................. 3-18 3-21 Main Igniter Power Switch ......................................................................................................................... 3-18 3-21 Maintenance ....................................................................................................................................................... 1-10 Maintenance Indicator ........................................................................................................................................... 3-3 MAINTENANCE INSTRUCTIONS ............................................................................................................... 5-2 5-19 Malfunction Remedy Table ................................................................................................................................... 6-4 MANDATORY SAFETY MEASURES ................................................................................................................... 1-5 MAT KONTROL® II WITH PADDLE SENSORS ................................................................................................... 10 MAT KONTROL® II WITH ULTRA 3s® SENSORS .............................................................................................. 10 Mat Reference Option ............................................................................................................................................ 17 Material Indicator (Option) .................................................................................................................................. 3-12 Material Indicator Kit Option ................................................................................................................................... 16 MISCELLANEOUS MAINTENANCE TASKS .....................................................................................................5-67 Miscellaneous Maintenance Tasks .....................................................................................................................5-18 Miscellaneous Specifications ................................................................................................................................ 7-4 Mode Switch ....................................................................................................................................................... 3-15 Monthly Maintenance Requirements .................................................................................................................. 5-16 Monthly Maintenance Tasks ............................................................................................................................... 5-35 Motor Shift Switch ................................................................................................................................................. 3-8 MOVING THE MACHINE - UNDER PROPULSION ........................................................................................... 4-11 MOVING THE MACHINE BETWEEN WORKSITES .......................................................................................... 4-15 Muffler Installation ............................................................................................................................................... 2-14 ,

,

,

-OOFF SEASON STORAGE .................................................................................................................................. 5-70 Oil Pressure Gauge .............................................................................................................................................. 3-5 Oil Temperature Gauge ........................................................................................................................................ 3-6 OMNISCREED® IA ................................................................................................................................................ 15 OMNISCREED® Specifications ............................................................................................................................. 15 Operating .............................................................................................................................................................. 1-9 OPERATING CONTROLS AND INSTRUMENTS ................................................................................................3-2 OPERATING INSTRUCTIONS ............................................................................................................................. 4-2 OPERATING THE MACHINE - GENERAL GUIDELINES ..................................................................................4-10 OPERATOR’S UMBRELLA ..................................................................................................................................... 7 OPTIONAL INSTALLATION GUIDELINES ........................................................................................................ 2-14 ORGANIZATIONAL MEASURES ......................................................................................................................... 1-4 OVERVIEW ........................................................................................................................................................... 1-3

W-4


WORD INDEX -PParking Brake - Operational Check .................................................................................................................... 5-35 Parking Brake Switch .......................................................................................................................................... 3-10 Perform the steps below to install the system .....................................................................................................2-29 Perform the steps outlined below to adjust the conveyors ..................................................................................5-30 PERIODIC MAINTENANCE ............................................................................................................................... 5-13 Physical Specifications ......................................................................................................................................... 7-2 Pivot Steer Switch ............................................................................................................................................... 3-11 PIVOT STEERING ................................................................................................................................................... 7 Positioning the Machine and its Controls .............................................................................................................. 4-4 Positioning the Material Truck and Starting to Pave .............................................................................................4-8 Positive Traction Switch ...................................................................................................................................... 3-10 POWER FLOW GATES ........................................................................................................................................... 8 POWER SLOPE OPTION FOR 2.5/5B HYDRAULIC EXTENSIONS .................................................................... 14 Pre-Start Checks and Verifications .......................................................................................................................4-2 PRE-START INSPECTION ................................................................................................................................... 1-6 Preventative Maintenance Checklist ................................................................................................................... 5-18 PROCEDURE WHEN RECEIVING THE MACHINE ............................................................................................... 2 PROPANE (LPG) HEATERS WITH ATIC ............................................................................................................. 13 Pump Drive Box - Change Fluid ......................................................................................................................... 5-59 -QQuarterly Lubrication and Service ....................................................................................................................... 5-16 Quarterly Maintenance Requirements ................................................................................................................ 5-16 QUARTERLY MAINTENANCE TASKS .............................................................................................................. 5-38 -RRadiator Hoses - Check ...................................................................................................................................... 5-46 RECOMMENDED SERVICE PARTS .................................................................................................................. 10-1 Rear Control Stations .......................................................................................................................................... 3-13 Rear Conveyor Bearings - Grease ...................................................................................................................... 5-20 REAR SUSPENSION .............................................................................................................................................. 7 Refilling Hydraulic System with Fluid .................................................................................................................. 5-57 Removal and Cleaning of Relief (In Hydraulic Tank) .......................................................................................... 5-54 RH and LH Conveyor Switches ............................................................................................................................ 3-9 RH Control Panel ................................................................................................................................................ 3-19 RH Flowgate Control Switch ................................................................................................................................. 3-8 -SSAFETY ................................................................................................................................................................ 1-2 SAFETY INSTRUCTIONS GOVERNING OPERATION ....................................................................................... 1-7 SCHEMATIC, ELECTRICAL.................................................................................................................................. 9-3 SCHEMATIC, HYDRAULIC ................................................................................................................................... 9-4 SCREED CHOICES/SCREED OPTIONS ............................................................................................................. 12 Screed Control Panels ........................................................................................................................................ 3-16 Screed Control Switch .......................................................................................................................................... 3-8 Screed Depth Cranks - Grease ........................................................................................................................... 5-32 Screed Extension In/Out Toggle Switch .................................................................................................... 3-19 3-20 SCREED HEATERS .............................................................................................................................................. 12 Screed Pivot Points - Grease .............................................................................................................................. 5-33 Screed Vibrator Shaft Bearings - Grease ...........................................................................................................5-21 Screed Vibrator Switch ....................................................................................................................................... 3-10 Securing the Machine to the Transporter (Tiedown) ........................................................................................... 4-15 Selecting a Site for Assembly ............................................................................................................................... 2-3 SELECTION AND QUALIFICATION OF PERSONNEL ....................................................................................... 1-4 Selector Switch ................................................................................................................................................... 3-16 ,


W-5

WORD INDEX Semi-Annual Lubrication and Service ................................................................................................................. 5-17 Semi-Annual Maintenance Requirements .......................................................................................................... 5-17 SEMI-ANNUAL MAINTENANCE TASKS ...........................................................................................................5-49 Short-Coupled Drive Shaft - Grease ................................................................................................................... 5-46 Slope/Grade Controller ....................................................................................................................................... 3-15 SMOKEEATER® VENTILATION CONTROL SYSTEM ........................................................................................ 10 Starter Button ........................................................................................................................................................ 3-7 Starting .................................................................................................................................................................. 1-8 Starting the Machine ............................................................................................................................................. 4-3 Steering Units ....................................................................................................................................................... 3-2 Stop Engine Indicator ............................................................................................................................................ 3-5 Stopping ................................................................................................................................................................ 1-9 Suggestions to Make Cleanup Easier ................................................................................................................... 4-3

-TTECHNICAL SPECIFICATION ............................................................................................................................. 7-2 Throttle Switch .................................................................................................................................................... 3-10 TOWING THE MACHINE ................................................................................................................................... 4-16 TRACTION DRIVE ................................................................................................................................................... 6 TRACTION LOCK SYSTEM .................................................................................................................................... 7 Transmission Shift Switch ..................................................................................................................................... 3-7 TROUBLESHOOTING .......................................................................................................................................... 6-2 TRUCK HITCH ......................................................................................................................................................... 7 Truck Hitch In/Out Button .................................................................................................................................... 3-11 Truck Hitch Option Rollers - Grease ................................................................................................................... 5-27 Truck Hitch Option Slides - Clean/Grease .......................................................................................................... 5-31 Truck Hitch Specifications ........................................................................................................................................ 7 -UUltraEye® V Grade Sensor Option ........................................................................................................................ 17 UNDERSTAND SIGNAL WORDS ........................................................................................................................ 1-2 Unloading the Machine ......................................................................................................................................... 2-3 Up/Down Indicators ............................................................................................................................................. 3-14 Up/Down Knob .................................................................................................................................................... 3-16 -VVentilation Control Switch ................................................................................................................................... 3-11 -WWait To Start Indicator .......................................................................................................................................... 3-3 Warning Indicator ................................................................................................................................................ 3-16 WARNING OF SPECIAL DANGERS .................................................................................................................. 1-13 WARNINGS .......................................................................................................................................................... 1-3 Washdown Fuel Filter - Change ......................................................................................................................... 5-66 WASHDOWN SYSTEM ......................................................................................................................................... 11 Water in Fuel Indicator .......................................................................................................................................... 3-4 Water Temperature Gauge ................................................................................................................................... 3-6 WEDGE-LOCK® SCREED .................................................................................................................................... 13 WEDGE-LOCK® SCREED EXTENSIONS ............................................................................................................ 14 Wedge-Lock® Screed Extensions Size and Options ............................................................................................. 14 Wedge-Lock® Screed Specifications ..................................................................................................................... 13 Weekly Lubrication and Service .......................................................................................................................... 5-16 Weekly Maintenance Requirements ................................................................................................................... 5-16 Weekly Maintenance Tasks ................................................................................................................................ 5-31

W-6


HIGHWAY CLASS PAVER WARRANTY Ingersoll-Rand Company (“IR”) warrants to its and its affiliates’ authorized dealers, who in turn warrant to the initial user only, that each new Ingersoll-Rand Highway Class Paver sold by the dealer will be free from proven defects in material and workmanship for a period of twelve (12) months from the in service date to the initial user or 1500 hours of service by the initial user, whichever occurs first. During the warranty period, an authorized distributor shall repair or replace, at IR’s option, any part that is found upon inspection to be defective in material or workmanship. Such part will be repaired or replaced without charge for parts and labor to the initial user by an authorized dealer. The initial user shall provide the authorized dealer with prompt notification of the defect and allow reasonable time for repair or replacement. IR may require failed parts to be returned to the factory. Transportation of the product to the authorized dealer is the responsibility of the user. The remedies provided in this warranty are exclusive. This warranty does not apply to failures occurring as a result of abuse, misuse, negligent repairs, corrosion, erosion and normal wear and tear, alterations or modifications made to the product without the express written consent of IR, or failure to follow the recommended operating practices and maintenance procedures as provided in the product’s operating and maintenance publications. This warranty does not cover replacement of scheduled service items such as oil, filters, and wear items. This warranty does not apply to engines (including engine electrical components) and tires or other accessories and equipment furnished by IR, but manufactured by others. The initial user shall rely solely on the warranty, if any, of the respective manufacturers thereof. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND CONDITIONS (EXCEPT FOR THE WARRANTY OF TITLE), EXPRESS OR IMPLIED. IR DISCLAIMS ALL OTHER WARRANTIES AND CONDITIONS, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTIBILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL IR OR ANY OF ITS AFFILIATES, SUBSIDIARIES OR AUTHORIZED DEALERS BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHATSOEVER, INCLUDING, BUT NOT LIMITED TO, LOSS OR INTERRUPTION OF BUSINESS, LOST PROFITS, OR LOSS OF MACHINE USE, WHETHER BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE, STRICT LIABILITY, STATUTE OR OTHERWISE, EVEN IF IR OR ANY OF ITS AFFILIATES, SUBSIDIARIES OR AUTHORIZED DEALERS HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THE TOTAL LIABILITY OF IR, ITS AFFILIATES, SUBSIDIARIES AND AUTHORIZED DEALERS WITH RESPECT TO THE PRODUCT FURNISHED HEREUNDER SHALL NOT EXCEED THE PURCHASE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS BASED, EXCEPT FOR CLAIMS FOR PERSONAL INJURY.

The undersigned acknowledges that he/she has received a copy of this warranty on the date set forth below. Initial user:

(Name of company)

By: Title: Date: CPN: 13858246

062105

PF161 Ops and Maint_13858741

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