Beruflich Dokumente
Kultur Dokumente
500 SERIES
Hot Mix Asphalt Paver
Covers All 552 & 562 Models
DANGER
Federal, state and local safety regulations aim to protect both people and property from
accident, injury and harmful exposure. When complied with, such regulations are often
effective. Hazards to personnel and property are further reduced when this equipment is
used in accordance with all operation and maintenance instructions. Generally:
(1) Read and heed all danger, warning, caution, and notice decals. Know what guards and protective
devices are included and see that each is installed and in operational condition. Additional guards and
protective devices may be required and must be installed by the user (owner) before operating.
(2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag
out all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make it
impossible for anyone to start this machine while others are working on it or in it.
(3) Wear personal protective equipment such as hard hats, ear plugs, safety glasses and safety shoes
when operating this equipment. Do not wear loose clothing or long hair.
(4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon
as you spot them. Never allow anyone to engage in horseplay when near this equipment.
DANGER
Failure to take these precautions will result in death or severe personal injury.
WARNING
Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and reproductive harm.
Wash hands after handling.
The following warning applies to equipment supplied with diesel powered engines:
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.
Cedarapids Inc, hereafter referred to as Cedarapids, warrants its new products manufactured and sold worldwide
to be free of defects in material or workmanship for a period of one (1) year, or 2000 hours of use, whichever occurs
first.
The warranty will commence on the day the equipment is put into operation by the customer for use, whether sold,
rented or leased or one (1) year after shipment from the factory, whichever occurs first. Delivery Inspection
forms are required for warranty validation and processing.
Cedarapids obligation and liability under this warranty is expressly limited to, at Cedarapids sole option, repairing
or replacing with new or remanufactured parts or components, any part which appears to Cedarapids upon
inspection to have been defective in material or workmanship. Such parts shall be provided at no cost to the user,
FOB a Cedarapids parts facility.
Cedarapids shall pay, to the extent outlined in the Warranty Reimbursement section, the cost of labor to install any
repaired or replaced part provided under this warranty.
This warranty may not apply to component parts or accessories not manufactured by Cedarapids and which carry
the warranty of the manufacturer thereof. Furthermore, normal maintenance, adjustments, or maintenance/wear
parts are not covered by this warranty.
Cedarapids makes no other warranty, express or implied, and makes no warranty of merchantability or fitness for
any particular purpose.
No employee or representative is authorized to change this warranty unless such change is made in
writing and signed by an authorized representative of Cedarapids.
Cedarapids obligation under this warranty shall not include duty, taxes, or any other charges whatsoever, or any
liability for direct, indirect, incidental, or consequential damage or delay.
If requested by Cedarapids, components or parts for which a warranty claim is made are to be returned to the
location designated by Cedarapids.
Improper maintenance, improper use, improper storage, operation beyond rated capacity, operation after discovery
of defective or worn parts, or alteration or repair of the equipment by persons not authorized by Cedarapids shall
render this warranty null and void. This warranty shall be null and void if parts other than genuine Cedarapids are
used in the equipment. Cedarapids reserves the right to inspect the installation of the product and review
maintenance procedures to determine if the failure was due to improper maintenance, improper use, operation
beyond rated capacity, operation after discovery of defective or worn parts, or alteration or repair by persons not
authorized by Cedarapids.
Replacement Parts Warranty: Cedarapids warrants the replacement parts ordered from the Parts Department to
be free of defect in material or workmanship for a period of 6 months or 1000 hours of operation, whichever occurs
first.
Extended Warranty: Extended warranties are available for purchase at the time of sale. The terms and
conditions of the Extended Warranty will be provided upon request.
TRANSFERABILITY OF WARRANTY: The balance, if any, of the original equipment warranty may be transfered
to second and subsequent owners provided certain conditions are met. Please contact your local Cedarapids
Dealer for additional details if needed.
Section 1 - Introduction
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Section 2 - Safety
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Symbols and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Hazard Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Decals and Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4
Danger and Warning Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7
Management Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7
Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7
Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8
Equipment & Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8
What is Lockout & Tagout? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9
When is Lockout & Tagout required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9
Who must apply a lock & tag? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9
When can a lock and tag be removed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9
Who can remove a lock and tag? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9
Screed Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 10
Training and Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 10
Safe Paver Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 10
Cutoff Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 17
Front Wheel Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 17
Proportional Material Feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 18
Sonic Feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 18
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 19
Engine start-up after stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 19
Jump-Starting/Charging Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 20
Emergency towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 20
Loading/Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 23
Driving the Paver off a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 23
Lifting With Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 25
Preparation for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 26
Preparing to Pave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 27
Fume Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 27
Nulling Screed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 28
Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 29
Transverse Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 29
Joint Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 29
Joint Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 29
Rubber Track Operating Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 31
Do Not Allow Asphalt Build-up on Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 31
Proper Installation of Material Retaining Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 32
Maneuvering On Hot Asphalt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 33
Maneuvering On Uneven Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 35
Maintenance of Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 37
Spray Down and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 40
Paver Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 40
Generation III Sonic Sensor Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 41
Pressure Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 41
Section 6 - Maintenance
Raising the hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 1
Before Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2
Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 3
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 4
1) Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 4
2) Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 4
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 4
Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 5
3) Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 5
4) Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 6
5) Suction Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 6
6) Charge Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 7
7) Auxiliary Pump Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 7
8) Hydraulic lines and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 7
9) Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 8
Rubber Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 40
Rubber Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 40
Rubber Track Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 41
Rubber Track Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 42
Rubber Track Re-tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 43
Repairing Rubber Track Bogie Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 44
Bogie Wheel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 44
Bogie Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 45
Bogie Wheel Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 45
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 45
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 45
Repairing Rubber Track Front Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 47
Front Idler Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 47
Front Idler Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 48
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 49
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 49
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 50
Front Idler Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 51
Rubber Track Drive Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 51
Slat Conveyor Paver, Slat Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 53
Replacing Slat Conveyor Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 53
Inverting Slat Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 53
Remix Paver Delivery Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 53
Replacing Auger Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 53
Replacing Auger Flights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 54
Paver Spreading Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 55
Cast Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 55
Re-facing Lined Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 55
Re-lining Auger Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 56
Machine Storage Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 56
Introduction
Section 2 - Safety
Introduction
This equipment is designed expressly for hot mix
paver operations. When our equipment is used for
purposes other than those for which it was
designed, user assumes sole responsibility for any
injuries or damage that may result from said
misuse. We emphatically recommend that this
equipment be operated only by personnel who are
trained in its use.
We make no guarantee, either expressly or by
implication, that this equipment meets all local or
federal safety regulations. It is the responsibility of
those individuals who own and/or operate this
machine to verify that all safety regulations are
complied with before starting either this unit or any
associated equipment.
Important symbols and hazard classification A multi-tier hazard classification system is used to
standards relating to safe equipment operation are communicate potential personal injury hazards.
used throughout this manual. Make sure you read, The following signal words used with the safety
understand and follow all DANGER, WARNING alert symbol indicate a specific level of severity of
and CAUTION decals on equipment. the potential hazard (Figure 2 - 2). Signal words
used without the safety alert symbol relate to
Safety Alert Symbol property damage and protection only. All are used
as attention-getting devices throughout this manual
The safety alert symbol (Figure 2 - 1) is used to as well as on decals and labels fixed to the
alert you to potential personal injury hazards. Obey machinery to assist in potential hazard recognition
all safety messages that follow this symbol to avoid and prevention.
possible injury or death.
DANGER indicates an imminently
DANGER hazardous situation which, if not
avoided, will result in death or
serious injury.
Decal Locations
3b
8-94
0441
3b
04418-94
NOTICE
Maintain proper tire pressure.
32 PSI recommended.
04493-017
Diesel
04418-135-11g
Diesel
04418-135-11g
3b
04418-94
FULL HOT
FULL COLD
RESERVOIR
LEVEL
04418-836c
Engine
Coolant
Drain
04418-950c
Engine
Oil
Drain
04418-720d
Paver Patents
Built under one or more of the following patents:
United States:
4,702,642 - 4,801,218 - 4,933,853 - 4,948,292 - 5,004,394 - 5,100,277 - 5,197,848 -
5,286,138 - 5,301,170 - 5,356,238 - 5,511,900 - 5,599,134 - 5,702,201 - 5,857,804 -
6,007,272 - 5,401,115 - 6,019,544
Canada:
1,260,752 - 1,302,439 - 1,313,078 - 2,181,969
A Terex Company
04418-866e
Hydraulic System:
Every 1000 hours or seasonally drain, flush, and refill.
Typical Brand Names
Amoco AW68 Chevron AW68 Exxon NUTO H68
Mobil DTE 26 Shell Tellus 68 Texaco Rando HD 68
Grease Fittings:
Use high temperature grease. See instruction sheet.
Typical Brand Names
Chevron Ulti-Plex Synthetic Exxon Unirex N2
Mobil Mobilith or SHC-460 Shell Retinax LC Texaco Premium RB
Safety
DANGER
04418-925
Vacuum Indicator
REAR VIEW
A Terex Company
Muffler
CEDAR RAPIDS, IOWA U.S.A. Fume
Recovery
SERIAL NUMBER Fan
Fume
Vacuum
Recovery
Indicator
Hood
MODEL NUMBER Engine
1. Check vacuum indicator daily.
2. Operate between 1 and 2 inches W.C.
3. Clean tubes and fan when indicator is outside limits.
DATE OF 4. Read Operation & Maintenance Manual.
MANUFACTURE
04418-934b
4493-023
FRONT VIEW
EMERGENCY
E M E R G E N C Y TOWING
T O W I N G INSTRUCTIONS
INSTRUCTIONS
Pressure guage
Porta-power
BRAKE RELEASE
1. Chock machine tracks or tires before proceeding.
2. Put travel pumps into bypass.
WARNING
3. Disconnect brake hose from solenoid valve, located on rear bulkhead
right hand side.
Solenoid Disconnect 4. Attach porta-power, tee and pressure guage to open hose end and
pressurize to release brake. To reapply brake, relieve pressure at
Emergency Towing
valve brake line
porta-power.
5. Maintain minimum of 350 psi to fully release brake. Do not exceed Keep paver from moving before
Rear bulkhead
1500 psi. releasing brakes.
Serious personal injury or equipment
TOWING PROCEDURE damage can result.
1. Use chains in good condition, capable of pulling 25 tons. Read manuals.
2. Open front conveyor bearing covers. Run chain through holes shown.
3. DO NOT ATTACH chains to push rollers or truck hooks to pull an 04491-026
Safety
DANGER
READ MANUALS
Read all manuals prior to operation.
DO NOT PERFORM these procedures if you do not understand
the information in the manuals.
Consult your supervisor, the owner or the manufacturer.
04494-103-01
NOTICE
To prevent damage to the electrical system
when using a booster battery or charger:
Always connect:
(+) Positive to Positive
(-) Negative to Negative.
04493-022
DANGER
Use cardboard or
paper to check
for leaks Skin Injection Hazard
If fluid is injected under skin,
Not your
gangrene can result.
hand! Get medical help immediately!
Safety
DANGER
ED
OUT
LOCK
EQUIP
PELIGRO
DANGER
READ MANUALS
DANGER
OUT ED
LOCK
04490-030a
HYDRAULIC RESERVOIR
AMOCO AW68
CHEVRON AW68
EXXON NUTO H68
MOBIL DTE26
SHELL TELLUS 68
TEXACO RANDO HD68
Personal Safety
Personal Safety Always lock out and tag out involved energy
sources before performing maintenance or
This equipment is designed with the safety of all adjustments on this equipment. Make it
personnel in mind. Never attempt to change, impossible for anyone to start this machine
modify, eliminate or bypass any of the safety while others work on it or in it.
devices installed at the factory. Guards, covers and
shields installed around moving parts at the factory Never remove any guard, cover or shield when
are meant to prevent accidental injury to operators this equipment is in motion.
and other personnel. Do not remove them. Replace guards, covers and shields when the
task for which you removed them is finished.
Block parts as necessary to prevent their
DANGER
sudden movement while people are working on
the machine.
Sometimes, at a customers request,
Never attempt to clear away jammed feed
equipment is shipped without
material, discharge material or other stoppage
certain features such as a drive
while the machine is running. Stop the
sheave. When this occurs, we attach
equipment, lock out and tag out before
a warning decal to alert installers
touching this machine with your tools or your
that the related guard or other safety
hands.
feature is missing. In such cases it is
the customers responsibility to Wear proper personal protective equipment,
guard the machine properly. including eye protection, hard hat and safety
shoes, whenever youre near this machine
We recommend the following basic safety while it is running.
practices:
Dress appropriately in every way. Never wear
loose clothes, long hair, coat tails, jewelry,
Management Responsibilities
pockets full of tools or any other item that could
Make sure that everyone working on or near get caught in moving parts.
this equipment is familiar with safety
Know where your fellow workers are. Always
precautions. Have a supervisor at the job site
look around and inside this machine before
responsible for job safety.
starting it. Make sure nobody is in the way of
Give crew members specific safety moving parts or working on the machine.
responsibilities and instruct them to report any
Lift with your legs, not with your back. Keep
unsafe conditions to their supervisor
the weight close to your body. If the load is
more than 40 lbs., get someone to help you.
Operator Responsibilities
Never engage in horseplay when near this
Read all danger, warning, caution and notice
machine, or any other.
signs.
Report any defective machinery or equipment
and unsafe conditions or activity to your boss
immediately.
Personal Safety
Dont limit safety practices to the few rules Equipment & Tools
listed here. Think safety and act safely at all
Clean tools that are properly labeled and stored
times.
are safer tools. Keep your tools in good order.
Most of all, know your equipment. Understand
Keep drive belts and sheaves in good condition.
the machinery, the conditions under which it
Frayed belts or cracked sheaves are not only
operates and what it is capable of doing.
dangerous, they cost you downtime.
Work Area Safety Always use mechanical assistance to lift heavy
loads. Never overload a hoist, crane, jack or
Keep the work area as neat and clean as
other lifting device. Check lifting tackle
practical.
regularly; replace it at the first sign of stretch,
Keep all product safety signs clean, clear and fraying or other wear.
current.
Keep your equipment clean, free of dirt and
Make sure all electrical equipment is properly grease, so that loose, cracked or broken parts
grounded. Wet spots near electrical current are are more easily spotted. Replace defective parts
especially dangerous. as soon as they are discovered.
Store hazardous materials in restricted access
areas and mark them clearly. Federal
regulations require special labeling of certain
materials.
Never start an engine in an enclosed space
without properly venting the exhaust.
Do not smoke or allow smoking near fuels and
solvents. Never strike a spark or use an open
flame near fuels and solvents.
Store flammable fuels, solvents and gases in
secure, well ventilated areas. Never allow
fumes to accumulate in the storage area. Use
nonflammable solvents for cleaning parts and
equipment whenever possible.
Know where fire extinguishers and other fire-
suppression equipment are located. Learn how
to use them effectively.
Be alert and wary around any pressurized
system, hydraulic or pneumatic. High-pressure
oils and gases are very dangerous.
What is Lockout & Tagout? When can a lock and tag be removed?
Lockout & Tagout is a procedure thats designed to After performing these six steps:
prevent the unexpected or accidental startup of 1) All safety guards are back in place.
equipment and to alert all workers whenever it is
unsafe to operate any piece of equipment. When 2) All work is complete and tools are put away.
used as intended, Lockout & Tagout also protects 3) All workers are notified that a lock is being
personnel from energy stored in devices such as removed.
springs, accumulators, batteries, hydraulic
systems, etc. 4) All workers are positioned safely for startup.
5) Controls are positioned for safe startup.
When is Lockout & Tagout required?
6) The machine is ready for safe operation.
Any time anyone is maintaining, repairing,
lubricating, or, for whatever reason, working on Who can remove a lock and tag?
the equipment.
Only the person who applied a lock and tag is
When the equipment is broken or, for whatever permitted to remove them.
reason, unfit or unsafe to operate.
Lockout & Tagout rules laid out here are generic.
While clearing blocked or jammed To get instructions for your particular workplace,
mechanisms. consult your employers lockout/tagout procedure.
Whenever the equipment is left unattended.
Proper training and equipment knowledge is Keep all personnel clear of augers when the
essential to the safe operation of this machine. paver is operating.
Carefully read the entire manual before attempting Do not refuel the paver with the engine or
to operate the paver. Keep this manual for future screed heater system running. All sparks and
reference. open flames must be kept a minimum of 50
feet away from the paver when refueling.
Do not wash or spray down the screed or
WARNING
tractor with the screed heater system
operating.
Do not operate this equipment until
Read, understand and follow all current
you have been trained in its
OSHA, federal, state and local regulations that
operation or maintenance. This
are applicable to your job and equipment.
equipment may only be operated or
maintained by trained personnel, This equipment must be used in accordance
who have demonstrated their ability with all operation and maintenance
to do so safely. instructions.
All persons involved with this equipment must
Safe Paver Operation
be familiar with this manual.
The following safety information concerns the
Read, understand, and follow all Danger,
operation of your paver.
Warning, Caution and instruction decals in this
book and on the paver.
Section 3 - Set Up and Operation If hidden damage is found after the carriers
representative has gone, do not continue to unpack
or move the equipment. Contact the carriers local
Receiving New Equipment
office and have the terminal manger or authorized
representative make an immediate personal
Pre-Operation Check
inspection of the damage. Obtain a written
description of the damage, and photos if possible,
Before accepting and unloading a new paver, the
signed by the representative as proof of a valid
consignee must inspect the equipment for evidence
claim.
of damage or missing parts. This inspection
process should be thorough, because once the
A packet of equipment warranty/start-up
freight receipt is signed, it is assumed that all of the
information will be sent to the distributor before
equipment listed on the receipt was received in
the equipment leaves the factory. All warranty/
good condition.
start-up forms must be filled out and returned to
Cedarapids within 24 hours after the equipment is
Make a thorough inventory of all loose components
received.
packaged in boxes. A check list is provided in each
box listing the components in the box. While
performing the inventory, inspect all loose Principle Of Operation
components for damage which may have occurred The paver will lay a uniform, high-density, asphalt
during transit. Any damage that happens to the mat for highways, roadways, airport runways,
equipment in transit is the responsibility of the parking lots and driveways. It is capable of
carrier not Cedarapids. Claims for damage must be performing jobs with strict control specifications
submitted to the carrier for settlement. and high production requirements.
When evidence of damage or loss is discovered, The paver will level and compact mix up to 12 in
have the driver make a notation on both the depth, with mat widths varying from 6 to 30. Mat
carriers and consignees copies of the freight bill. depth and width variations are accomplished by
Prior to signing the freight bill, take pictures of the adjusting feed controls and adjusting the screed.
damage and identify the truck if possible. The The hot mix is dumped by truck into the hopper or
consignee can then sign the bill to acknowledge picked up by a windrow machine at a rate suitable
delivery. The consignee should then have the for continuous paving. While dumping mix, the
carriers terminal manager or his authorized truck is pushed forward by the paver.
representative make an official inspection of the
damage or loss. For the Slat Conveyor Paver, (Figure 3 - 1) hot mix
is carried by two independently controlled slat
Equipment should not be moved from the original conveyors to the augers at the rear of the tractor and
receiving point until this official inspection has in front of the screed. Material feed may be either
been made. Good clear photos will verify and manually or automatically regulated to maintain an
explain damage in any claim action which may even and consistent head of material in front of
follow. When the inspection is done, the consignee the screed. Material flow rate is regulated by a
should file a written damage claim with the combination of varying slat conveyor speed and
carriers office and should report this action to the material gate height.
area distributor for Cedarapids Inc.
Principle Of Operation
For the Remix Paver, (Figure 3 - 2) two sets of distribute material along the entire width of the
counter-rotating delivery augers remix the hot mix screed. Material feed may be either manually or
as it is conveyed to the spreading augers at the rear automatically regulated to maintain an even and
of the tractor. The speed of each set of delivery consistent head of material in front of the screed.
augers is controlled independently to maintain the
proper level of material. The spreading augers
Hopper
Screed
Material Gate
Slat Conveyor
Spreading Auger
Screed
Hopper
Spreading Auger
Delivery Auger
A strike off plate mounted directly in front of the The screed can be fitted with extensions or
screed bottom meters the material passing under extendible strike-offs for paving wide widths or
the screed bottom. The screed rides up or floats on shoulders.
the mix to level and smooth the mat. Contour of the
mat may be set to a desired slope with the Fume Recovery System
adjustable screed controls. Screed controls are
adjusted manually or automatically to create the The fume recovery system is designed to collect
desired mat. fumes given off by hot mix asphalt and discharge
them away from operator work areas. This system
The screed bottom flexes at its midpoint into a is standard equipment on all pavers. (Figure 3 - 3)
slight V-shape (negative crown) or into a slight The system is designed to collect fumes given off
inverted V-shape (positive crown). Such by asphalt mix as it is distributed along the length
adjustment produces a negative or positive crown of the main screed by the spreading augers. The
on mat for specified water drainage requirements. fumes are drawn into a hydraulically driven fan.
The screed has vibrators which perform the initial The fan then blows the fumes into the engine
ironing of the mat. Final compaction of the exhaust muffler. Inside the muffler the asphalt
newly laid mat is accomplished by a roller. fumes are combined with the engine exhaust and
discharged through the exhaust pipe. A vacuum
The screed has burners that heat the screed bottom
gauge indicates amount of vacuum generated in the
close to the temperature of the mix before paving
fan intake manifold.
begins. Heating the screed bottom prevents asphalt
from sticking to the screed bottom which causes
tearing and a poor mat surface.
Vacuum Indicator
2 4 6 8
0 10
INCHES W.C.
Fume Muffler
Recovery
Hood
Fume Engine
Recovery
Fan
Operators Console
Centering Lock
Operators Console
2 34
1 33
9 11 25
12
3 27
26
13 16
4
14
29
5
15
6 23 17 18
28
8 31
10 19 20 21 22 24 30 32
1) Oil Temperature Gauge 13) Lights Switch 25) Oil Pressure Gauge
2) Voltmeter Gauge 14) Flasher Switch 26) Brake Switch
3) Mix Flow Indicators 15) Eng. Diag. (ON-OFF) Sw. 27) Water Temperature Gauge
4) Hopper Switch 16) Range Travel Switch 28) Throttle Switch
5) Truck Hitch Switch 17) Screed Extension Switches 29) Horn Switch
6) Gates Switch 18) Rear Frame Switch 30) Steer Assist Switch
7) N/A 19) Engine Switch 31) Travel Joy Stick
8) Feed Override Switches 20) Vibrators Switch 32) Paver Speed Pot
9) Fuel Level Gauge 21) Screed Lift Switch 33) Emergency Stop Switch
10) Alarm Indicators 22) Screed Assist Switch 34) Fuel Switch
11) Hour/Tachometer 23) Eng. Diag. (INC-DEC) Sw.
12) Alarm Switch 24) Differential Lock Switch
Operators Console
2
1 33
9 11 25
12
3 27
26
13 16
4
14
29
5
6 15 17 18
23
28
31
10 19 20 21 22 24 30 32
1) Oil Temperature Gauge 13) Lights Switch 25) Oil Pressure Gauge
2) Voltmeter Gauge 14) Flasher Switch 26) Brake Switch
3) Mix Flow Indicators 15) Eng. Diag. (ON-OFF) Sw. 27) Water Temperature Gauge
4) Hopper Switch 16) Range Travel Switch 28) Throttle Switch
5) Truck Hitch Switch 17) Screed Extension Switches 29) Horn Switch
6) Gates Switch 18) Rear Frame Switch 30) De-Tracked Indicator
7) N/A 19) Engine Switch 31) Travel Switch
8) Feed Override Switches 20) Vibrators Switch 32) Paver Speed Pot
9) Fuel Level Gauge 21) Screed Lift Switch 33) Emergency Stop Switch
10) Alarm Indicators 22) Screed Assist Switch
11) Hour/Tachometer 23) Eng. Diag. (INC-DEC) Sw.
12) Alarm Switch 24) Differential Lock Switch
Operators Console
2
1 33
34
9 11 25
12
3 27
26
13 16
4
14
29
5
6 15 17 18
23
RH RATIO LH
28
7
8 31
10 19 20 21 22 24 30 32
1) Oil Temperature Gauge 13) Lights Switch 25) Oil Pressure Gauge
2) Voltmeter Gauge 14) Flasher Switch 26) Brake Switch
3) Mix Flow Indicators 15) Eng. Diag. (ON-OFF) Sw. 27) Water Temperature Gauge
4) Hopper Switch 16) Range Travel Switch 28) Throttle Switch
5) Truck Hitch Switch 17) Screed Extension Switches 29) Horn Switch
6) Remix Switch 18) Rear Frame Switch 30) Steer Assist Switch
7) Ratio Pots 19) Engine Switch 31) Travel Joy Stick
8) Feed Override Switches 20) Vibrators Switch 32) Paver Speed Pot
9) Fuel Level Gauge 21) Screed Lift Switch 33) Emergency Stop Switch
10) Alarm Indicators 22) Screed Assist Switch 34) Fuel Switch
11) Hour/Tachometer 23) Eng. Diag. (INC-DEC) Sw.
12) Alarm Switch 24) Differential Lock Switch
Operators Console
1 2 33
9 11 25
12
3 27
26
13 16
4
14
29
5
6 15 17 18
23
28
RH RATIO LH
31
10 19 20 21 22 24 30 32
1) Oil Temperature Gauge 13) Lights Switch 25) Oil Pressure Gauge
2) Voltmeter Gauge 14) Flasher Switch 26) Brake Switch
3) Mix Flow Indicators 15) Eng. Diag. (ON-OFF) Sw. 27) Water Temperature Gauge
4) Hopper Switch 16) Range Travel Switch 28) Throttle Switch
5) Truck Hitch Switch 17) Screed Extension Switches 29) Horn Switch
6) Remix Switch 18) Rear Frame Switch 30) De-Tracked Indicator
7) Ratio Pots 19) Engine Switch 31) Travel Switch
8) Feed Override Switches 20) Vibrators Switch 32) Paver Speed Pot
9) Fuel Level Gauge 21) Screed Lift Switch 33) Emergency Stop Switch
10) Alarm Indicators 22) Screed Assist Switch
11) Hour/Tachometer 23) Eng. Diag. (INC-DEC) Sw.
12) Alarm Switch 24) Differential Lock Switch
Operators Console
3) Mix Flow Indicators - Sensors on the gates The Truck Hitch switch is spring-loaded to
cause indicator lights on control panel to light return to the neutral position when the switch
when material is not contacting sensors. Each is released. To engage the truck, hold the
conveyor has a separate sensor and indicator. switch in Engage until the truck is in place,
then let the switch return to neutral to
4) Hopper Switch - The hopper raise switch is hydraulically lock the truck. To unhitch, place
spring-loaded to automatically return to the the switch in the Release position.
neutral position when released. It must be held
in the Raise or Lower position to control The truck hook is equipped with an adjustable
the hopper wings. needle valve on the front bulkhead which
controls the speed that the truck hook engages
5) Truck Hitch Switch - The optional truck hitch the trucks wheels. Rotate the needle valve
switch holds the truck in position at the front clockwise to reduce the engage speed and
of the paver so little or no material is spilled counterclockwise to engage the truck hook
after a truck is captured. The truck driver does quicker.
not have to ride the brakes to stay firm against
the paver.
Operators Console
Operators Console
13) Lights Switch- Push up to turn headlights on P/2 - Wheeled Paver. Use the P/2 position for
High, down for Low, or center for Off. paving in normal drive.
Work lights are turned on when the switch is in
P/4 - Wheeled Paver. (If paver not equipped with
High or Low setting. A rotary switch on
this option, it operates the same as for P/2.) Use
each work light changes light from red, white,
the P/4 position to change to front wheel assist.
and off.
Engaging the optional front wheel assist will
reduce the paver speed by 30%.
14) Flasher Switch- Push up to turn flashers
On, down to turn flashers Off. On 400
The paver must be stopped before changing from
series pavers this switch also turns on the
Travel to Pave, P/2, or P/4, or back the
strobe warning light mounted in the rear center
opposite way.
of the paver.
Operators Console
19) Engine Switch - The engine will start only if 23) Engine Diagnostic (INC-DEC) Switch -
the brakes are engaged, the travel lever/switch This spring-loaded switch incrementally or
is in neutral, and the Master Key is On. decrementally identifies multiple faults, using
three-digit coded, unique, numerical flashing
20) Vibrators Switch - The vibrator switch will for each, identified fault. It is used in
function only when the travel lever/switch is conjuntion with the Eng. Diag. ON-OFF
forward. Push up to turn vibrators On, down switch, (15) above, to identify multiple faults.
to turn vibrators Off. Pushing it to INC, advances fault identification
from the initial fault code to the second one.
21) Screed Lift Switch - Push up to Raise the This remains true, until the switch returns to
screed, down to Lower the screed, or center the mid position. Pushing it a second time
for Neutral. After the screed is raised to the advances it to a third fault. This can be
desired height and the switch is released, it repeated, until all individual fault codes have
returns to the hold position. The screed is been flashed. Letting the switch return to the
hydraulically locked at that height. While mid position and pushing it up again after all
paving, the switch must be set in the Lower fault codes have been flashed causes the last
float position. fault code to be repeated. After fault codes
have been incremented beyond the initial one,
22) Screed Assist Switch - Pavers equipped with pushing the switch down to the DEC position
power extending screeds (Fastach II, Stretch causes the fault codes to be decremented, one
16, Stretch 18, Stretch 20) have a Screed at a time, in the same way as for the INC
Assist system that allows adjustment of the switch position.
screed bearing pressure on the mat. Once
turned on, the screed assist should be left on. 24) Differential Lock Switch - (Wheeled paver)
Do not switch the screed assist on and off In wet or slick conditions one wheel could lose
while the paver is in motion. The screed assist traction and begin to spin. By activating the
should only be turned on when the screed is optional differential lock switch, both rear
resting on the ground and should be turned off wheels will rotate at the same speed regardless
prior to raising the screed. of how much traction each wheel has.
Operators Console
26) Brake Switch - The brake switch engages and 31) Travel Switch - (Track paver) Moving the
releases the brakes. Brakes will not release switch forward or back moves the paver in the
until sufficient system pressure is built up and desired direction.
the switch is set to the Release position. Do
not use for routine braking. Use only for 32) Paver Speed - This dial is used to govern the
parking and emergency stops. maximum travel speed of the paver. The travel
lever (wheeled paver) provides variable speed
27) Water Temperature Gauge - Indicates engine up to the setting on the speed dial.
coolant temperature. Normal operating
temperature = 205 F. Engine will shut down if Maximum speed for the wheeled paver is
engine coolant temperature exceeds 223 F. about 150 feet/minute paving speed (46
meters/minute) and about 12 miles/hour travel
28) Throttle Switch - The engine has only two speed (20 km/hour).
speeds. Use Idle to start and warm up the
engine, hydraulic oil, and screed. Use Full The track pavers have a maximum paving
position for all other functions. Switch to speed in excess of 150 feet/minute and a
Full only after engine and hydraulic oil have maximum travel speed of about 5 miles/hour
warmed up. (9 km/hour) for steel track. The rubber track
paver maximum travel speed is about 10 miles/
29) Horn Switch - Push up to sound the horn. hour (16 km/hour). A setting of five will be
When the switch is released, it will return to about half maximum speed.
the Off position.
With the Max Paver Speed dial at zero and
30) Steer Assist - (Wheeled paver) The steer travel lever/switch forward, the paver should
assist switch is spring-loaded to return to not move. This is used to test the auxiliary
center. When the switch is activated to one side systems.
or the other, the system slows the inside rear
drive motor while continuing to drive the other 33) Emergency Stop Switch - This push-button
motor at regular speed. This has the effect of switch, when activated, immediately shuts
abruptly steering the paver in the direction the down all paver systems.
switch is pushed.
34) Fuel Switch - (Wheeled paver) This switch
30) De - Tracked Indicator - (Track paver) transfers fuel flow and fuel level indication
Indicates when paver de-tracked condition/ between the left and right-hand fuel tanks.
correction situation exists.
Optional Equipment
Optional Equipment
Screed Extension
Screed extensions are furnished in 6",12, 24" and
36" lengths which make it possible to pave widths
up to 30'. Both screed and auger extensions can be
quickly attached. It is recommended that auger
extensions be 1' less than the screed extensions Strike-off
used. For example; with a 1' screed extension no
auger extension is needed, with a 2' screed
extension use a 1' auger extension, etc. (Figure 3 -
Figure 3 - 10 Slopeable Hydraulic Strike-off Extension
9)
Truck Hook
Extension
The truck wheels ride against the push rollers
which pushes the truck ahead of the paver. To
prevent the truck from pulling away from the paver
while moving down a hill, retractable rollers hook
into the inside of the truck wheels. (Figure 3 - 11)
Truck Hook
Figure 3 - 9 Screed Extension
Optional Equipment
Automatic Grade and Slope Control This kit includes four high pressure sodium lamps
and a separate generator to light up the work area at
The grade and slope control enables the paving night. (Figure 3 - 14)
contractor to lay uniform and smooth mats
automatically, regardless of irregularities in the
roadway. It also provides precise slope angle for
curves in roadway.
Grayhound
Optional Equipment
Optional Equipment
Auger Extensions
Cutoff Shoe Screed Bottom
End Gates are mounted on the end of the screed, Gives paver up to 50% more tractive effort with the
extension, or extendable strike-off. They prevent flip of a switch on the operators control panel on
material from spilling out beyond the reach of the the Wheeled Paver. (Figure 3 - 21)
screed and form a good edge on the mat.
(Figure 3 - 19)
Front
Wheel
End Gate Assist
Optional Equipment
15 15 15 30 50
POWER
2) Once the engine starts, release the Engine
OFF
15 15
15 15 FLASHERS
GATES
BURNER
LIGHTS
H
G J
F A B
C
E D
position..
After engine start, allow it to idle for at least 5
Master Switch
minutes to warm up before bringing the engine to
full throttle.
3) Set the console switches and controls as Under certain conditions the engine could stall
follows: while under load.
Jump-Starting/Charging Batteries
WARNING
WARNING
It is critical that the last cable connected
and the first cable disconnected be the
Batteries give off explosive hydrogen gas
negative (-) cable. Make the negative (-)
when charging. Keep flame and sparks
cable connection as far away from the
away from the battery while jump-starting
battery as possible. Connecting and
or charging.
disconnecting jumper cables or a battery
charger to and from a battery could cause a
spark and ignite the hydrogen gas that is
NOTICE produced by the battery.
Emergency towing
If your paver becomes disabled, and the engine can
not be started, it may be necessary to tow the paver.
Pavers have a parking brake that automatically
engages anytime the engine is not running. Before
towing a paver, the brakes must be released, and
the travel pumps put into bypass.
Positive Negative
Jumper Cable Jumper Cable
WARNING
Figure 3 - 25 Jumper Cable Connection Points Read all of the towing instructions before
starting this procedure.
WARNING
WARNING
Remix Pavers:
1) Insert an allen wrench into the internal hex of
each system check relief valve plug and remove
plugs. (Figure 3 - 27)
Disconnect
2) Remove valve poppet assemblies from each port Brake Line
and set aside in a clean, safe place.
3) Reinstall plugs on each port.
4) (Not used.)
System Check
Relief Valve
Plugs Port B
System Check
Relief Valve
Port A
All Pavers:
Loading/Unloading
NOTICE NOTICE
Maintain a minimum of 350 psi to fully Pulling the paver faster than 25 feet per
release the brakes. Do not exceed 1500 psi. minute can result in serious and expensive
damage to the travel system.
Loading/Unloading
NOTICE
Figure 3 - 30 Attaching chain for towing
Loading/Unloading
Loading/Unloading
WARNING
CAUTION
Preparing to Pave
Fan
Proportional
Feed Sensor
Mounting Hole
Fixed Fume
Control Hood
Sections
Proportional Feed Sensor Mounting Hole Fixed Fume Control Hood Sections
Preparing to Pave
Nulling Screed
Manual
NOTICE Depth
Cranks
Preparing to Pave
Joints
There are two types of joints that are constructed in
a paving operation, Longitudinal and Transverse. Remove
Proper construction of these joints is important not
only in producing a smooth rideable surface but
also in how they resist penetration of water, air and
other substances that would cause a premature
failure of the joint. (Figure 3 - 42)
Joint Construction
The next step to proper joint construction is placing
Figure 3 - 42 Types of Joints
boards or lath that equal the amount of compaction
in the joint area. (Figure 3 - 44) Remember
Transverse Joints compaction rates change due to thickness of
material & material design. Once the compaction
Transverse joints are created when an existing mat rate has been determined and the correct thickness
or lane is to be continued. The quality and of lath has been acquired, place the lath at the edge
durability of the joint depends on careful of the joint to elevate & support the screed to the
preparation of the existing mat or lane. It is critical correct starting level.
that any taper or defective area be removed.
NOTICE
Preparing to Pave
Remove Overlap
The following are some specific considerations for During paving, asphalt sometimes flows down to
operation of asphalt pavers equipped with rubber the rear drive wheel and become packed between
tracks. While not all-inclusive, following these the track and wheel. This may cause the following
recommendations should reduce the risk of problems:
problems and improve rubber track durability and Oil in the asphalt will cause the rubber in the
reliability. (Figure 3 - 47) track to soften and reduce the durability.
Aggregate will abrade the rubber in the track
and shorten its life.
Asphalt material build-up in the undercarriage
will cause additional tension on the track.
Asphalt Build-up
May Cause........
Guide Crush
Material retaining
plates retracted
Guide Wear
will allow material
to carry back
around to tracks.
Extend plates to
prevent this.
Proper Installation of Material Retaining Before paving begins, loosen nuts, slide plate out
Plates from frame and re-tighten nuts to hold plate in
position. (Figure 3 - 49)
Machines are shipped with the material retaining
plates as shown in (Figure 3 - 48). To work
properly, the plates must have the bottom edge of
the plate below the bottom edge of the machine
frame bulkhead and be extended.
Material retaining
plates
repositioned.
De-tracking
Damage
Rubbing
Marks on
Frame
Temporary
De-tracking
Figure 3 - 50 De-tracking
Tearing
Chunking
NOTICE
Releasing Paver Track Tension for long 4) Insert an allen wrench into the adjusting screw
term storage. As is true for covering the track, and turn it clockwise to close the valve.
releasing the track tension when the machine is
idle for an extended length of time, such as 5) Tighten jam nut on tension release valve
over Winter, will prolong its life. cartridge (Figure 3 - 55).
Tension
Release
Cartridge
Check track alignment. Rubber track 4) Periodically check that any steel cable or ply
undercarriage component alignment is very cord are not exposed.
important to the life of the track. An easy,
quick check is to inspect the track center lugs. 5) Periodically check that track is properly
(Figure 3 - 56) If one side is worn more than tensioned. A loose track could cause de-
the other side, one or more of the following tracking. (Refer to Tension information in the
conditions could exist. Factors such as asphalt Operation and Maintenance Manual.
build-up on the track inner surface, road
crown, track tensioning, etc. If any of the
above is present, correct the situation before
excessive track wear occurs.
Guide
Lug
Wear
on One
Side
Spray Down and Cleaning hoses, cables, tires and/or rubber tracks
with solvent as this may cause premature
Paver Cleaning Procedure deterioration.
Cleaning the paver is extremely important to keep 1) Run slat conveyors/remix augers until all mix
the chains and augers free and prevent build-up of is out of the hopper. Remove any piles or large
asphalt. Clean the paver thoroughly each day or chunks of mix from the paver and screed.
any time the paver will be stopped for an extended
period of time. 2) Clean all parts which come in contact with hot
mix. The paver must be completely cleaned,
even if the paver was used for a short time.
NOTICE
3) Start cleaning at the truck hook/push rollers
Hot mix gets hard quickly. Do not allow and work your way to the rear of the machine
mix to cool in the hopper. Run remix augers cleaning the hopper wings, slat conveyors/
to remove all material from the hopper any remix augers, hopper gates, spreading augers,
time the paver will be stopped for an screed bottom, end gates, strike-offs, etc.
extended period of time. (Figure 3 - 58)
WARNING
WARNING
Remix Paver
NOTICE
Keep solvent spray away from all electrical Figure 3 - 58 Shaded areas to be sprayed down daily
components, rubber parts and engine
compartment. Do not spray the paver when
it is parked on the mat. Move it to the side
of the road for drainage of solvent and
dissolved mix. Avoid spraying rubber
2) Before cleaning, turn off power to the sonic 1) Do not use a steam cleaner. Steam cleaning
control. Disconnect sensor cable from control can damage seals, bearings, gearboxes, and
unit and remove sensor from its mount. Install electrical components.
protective caps on all electrical connectors.
2) Do not use an acid-based solvent with the
pressure washer. Use only mild detergents or
degreasers.
3) Do not spray directly at electrical components, 5) Use extreme caution when spraying in the
seals, bearings, gearboxes, or hydraulic engine compartment. The engine compartment
cylinder rods. Water can be forced into is full of electrical and hydraulic components
electrical connections or the hydraulic system which could be damaged by high pressure
which could damage the system. water. Use a commercial engine cleaning foam
to remove dirt and grease from the engine
4) Do not spray the screed or engine until it is compartment.
cool. Spraying a hot screed bottom with cold
water could warp the screed bottom. Spraying 6) If you must spray near electrical or hydraulic
cold water on a hot engine manifold could components, cover the components before
crack the manifold. spraying.
The control system can show and record operation See panel layout with switches and indicator lamps
anomalies that present themselves as fault codes. below (Figure 4 - 1).
These codes will make troubleshooting easier. The See Item 10) Indicators page 3-10 for descriptions.
fault codes are recorded in the ECM. They can be
read using the fault lamps on the operators console
or with the Cummins INSITE service tool.
NOTICE
Fault Code Description 3) When the number has finished flashing from
the STOP lamp, the WARNING lamp will
The fault code will flash in the following sequence:
appear again.
1) The WARNING lamp will flash. This three-digit code will repeat in the same
sequence. (Figure 4 - 2)
2) After a 1 to 2 second pause, the STOP lamp
will flash out the number of the recorded fault
code. There will be a 1 to 2 second pause
between each number.
Switches
P=Pause 1 Flash P 2 Flashes P 4 Flashes P 4 Flashes P 1 Flash
Fault Code 244
Figure 4 - 2 Example Fault Code Sequences
Display of Fault Codes If only one active fault is recorded, the control
system will continuously display the same fault
The lamps flash each fault code out two times
code, even when the switch is moved to the INC or
before advancing to the next code.
DEC position.
To skip to the next fault code sooner:
General Description
Section 5 - Hydraulic System One pump supplies all auxiliary functions such as
hopper wings, truck hook, tow point cylinders, tow
arm cylinders, steering cylinders, frame raise
General Description
cylinders, screed assist (if equipped) and screed lift
cylinders.
Slat Conveyor Pavers Hydraulic Circuits
One tandem pump supplies the fume recovery fan
The separate hydraulic circuits in the Slat
motor and screed vibrators from one section as well
Conveyor Paver are supplied by the pumps shown
as the engine and hydraulic cooling fan from the
below in (Figure 5 - 1).
other section. This pump is mounted and driven
Two pumps drive the travel motors (one circuit for directly off the engine front gear housing.
each drive). This includes the front wheel assist on
The optional generator pump supplies the
tire pavers with this equipment.
generator drive motor circuit if the paver is
Two pumps drive the conveyors (one circuit for equipped with an electric screed or a generator to
each side). power lights or other electrical devices. This pump
is added to the right side pump stack.
FRONT
5
7
General Description
Remix Pavers Hydraulic Circuits One pump supplies all auxiliary functions such as
hopper wings, truck hook, tow point cylinders, tow
The separate hydraulic circuits in the Remix Paver
arm cylinders, steering cylinders, frame raise
are supplied by the pumps shown below in (Figure
cylinders, screed assist (if equipped) and screed lift
5 - 2).
cylinders.
Two pumps drive the travel motors (one circuit for
One tandem pump supplies the fume recovery fan
each drive). This includes the front wheel assist on
motor and screed vibrators from one section as well
tire pavers with this equipment.
as the engine and hydraulic cooling fan from the
Two pumps drive the delivery augers (one circuit other section. This pump is mounted and driven
for each side). directly off the engine front gear housing.
Two pumps drive the spreading augers (one circuit The optional generator pump supplies the
for each side). generator drive motor circuit if the paver is
equipped with an electric screed or a generator to
power lights or other electrical devices. This pump
is added to the right side pump stack.
Hydraulic Fluid Reservoir throughout the day, just as he does the engine oil
pressure, coolant temperature, voltage, etc. Normal
The reservoir holds hydraulic fluid for all systems,
operating range is 120 to 160F. Any time the
and one cooler maintains an operable fluid
hydraulic fluid temperature approaches or exceeds
temperature. It is located beneath the hood at the
180F, stop paving, determine the cause and
front of the engine compartment and under the
correct as necessary.
hydraulic pump stacks. The reservoir fluid capacity
is 75 gallons. Baffles divide the inlet sides from the
outlet sides. The baffles reduce oil foaming and air Slat Conveyor Pumps
suspended in the oil which can damage pumps. A Each conveyor motor is driven by a separate
breather is located on the top of the reservoir to conveyor pump. Each conveyor pump is made up
release pressure that builds up as the oil heats up of a variable displacement main pump and a charge
and cools down. The breather should be kept clean pump. The charge pump draws oil from the
to allow air flow through it. reservoir and outputs the oil at 340 PSI minimum
A drain hose is connected to the reservoir to make (380 PSI on right side for Rubber Track only). The
changing the hydraulic fluid convenient. The hose oil is filtered and routed into the intake of the main
is mounted to the rear bulkhead of the paver. When pump. The main pump supplies 3800 PSI
draining the reservoir, remove as much of the old maximum pressure directly to the conveyor motor.
fluid as possible. If the pressure goes over 3800 PSI the relief valves
open and bypass fluid to the reservoirs.
NOTICE Conveyor Drive Systems
Each slat conveyor/auger combination has its own
All filter elements and suction hose fittings
hydraulic drive. The augers are linked to the slat
should be checked and tightened regularly
conveyors by chain drive. A speed reducer is
to avoid leaks and prevent air from entering
located between motor and the chain drive.
the hydraulic system. Prolonged operation
with air in a hydraulic system will result in
damage to a pump and poor system
performance. NOTICE
Hydraulic Oil Cooler All pressure tests must be made with the
The pavers use a remote-mounted oil cooler, hydraulic oil at operating temperature.
mounted to the hood, with a hydraulically driven
cooling fan to maintain an operable fluid Cleaning a Disabled Paver
temperature. If the paver becomes disabled with the hopper full
of mix, the mix must be shovelled out of the hopper
Fluid Temperature and the conveyors must be cleaned out before the
Excessively hot hydraulic fluid is an indicator of mix cools.
trouble developing in the hydraulic system. An To remove the mix from the conveyors:
operator should make it a habit to check the
hydraulic oil temperature reading periodically
1) Rotate the conveyor pump bypass valve Checking Conveyor Drive Charge Pressure
counterclockwise no more than two turns.
Check pressure at output port on charge filter.
(Figure 5 - 3)
(Figure 5 - 5) The pressure should be 385 +/- 45 psi
at FULL throttle.
Bypass Valve
2) Run a chain under the paver from the front to Travel and Conveyor Charge
the rear. Attach chain to the slat at the bottom Pressure Test Ports
rear. (Figure 5 - 4) Figure 5 - 5 Charge Pressure Test Ports
5) Tow the paver forward away from the pile of Charge Pressure
Relief Valve
mix, reattach the conveyor chain, and repeat
this procedure until the hopper is completely Figure 5 - 6 Charge Pressure Relief Valve
empty.
Conveyor Neutral Adjustment 1) Install a low pressure line (500 psi min.)
connecting servo port F (Figure 5 - 8) and
Should a slat conveyor creep when the conveyor
servo port G (Figure 5 - 9). This removes the
switch is OFF, the neutral setting must be
effects of any control pressure on the servo
readjusted. These are factory set and normally will
piston.
not need adjustment. If neutral adjustment becomes
necessary, perform the following procedure. Refer
2) Install pressure gauges (10,000 psi) in the
to (Figure 5 - 8) through (Figure 5 - 11) during this
system pressure gauge ports (Figure 5 - 8).
procedure.
Start the engine and run at full throttle.
Position B
Neutral
Position
Position A
G Servo Port
Figure 5 - 10 Servo Neutral Position
Servo Neutral Adjustment
5) Rotate the servo neutral adjusting screw
Figure 5 - 9 Conveyor Pump Ports (Alternate View) clockwise half the distance between positions
A & B. The control should now be in a
neutral position. In this position the gauges
should read the same pressure (case pressure.)
6) While holding the servo neutral adjustment 10) Turn the control neutral adjustment screw
screw from turning, torque the servo lock nut clockwise until one of the system pressures
13 to 18 ft. lbs. Stop the engine and remove the starts to increase. Note the position A of the
servo cross-port line. internal hex wrench.
5) Insert an internal hex wrench into the pressure Each travel motor is supplied by a separate travel
adjusting screw. pump. Each travel pump is made up of a variable
displacement axial piston main pump and a charge
6) Move the Feed Conveyor Override switch on pump. The charge pump draws oil from the
the operator console to the OVERRIDE reservoir and outputs the oil at 340 PSI minimum.
position. The pressure readings on one of the The oil is filtered and routed into the intake of the
pressure gauges should rise and remain steady main pump. The main pump supplies 6100 PSI
when it reaches the pressure limiter setting. maximum pressure directly to the travel motor. If
the pressure reaches 6100 PSI, the pump destrokes
7) Rotate the pressure adjusting screw with the to reduce the flow rate and maintain the 6100 PSI
internal hex wrench, until a 5000 PSI reading pressure setting.
is reached on the pressure gauge.
Travel Drive Systems
The travel drive system permits infinitely variable
NOTICE speed adjustment from zero to maximum with
torque available for any normal paving load. The
speed will be maintained within the governed
Clockwise rotation of the pressure allowance whether the paver is pushing a loaded
adjustment screw will increase the pressure truck uphill or emptying the hopper. There will be
setting, counterclockwise rotation will no acceleration downhill even when hooked to a
decrease the pressure setting. Each loaded truck.
complete rotation of the pressure adjusting
screw changes the pressure setting by 1350
PSI.
2) Install two 10,000 PSI pressure gauges in the Figure 5 - 16 Multi-function Valve Adjustments
6) Move the direction control on the operators reverse setting rather than the forward setting
console to the forward direction. Slowly and all adjustments will be made to the reverse
increase the speed setting on the speed dial. pressure adjustment. Pressure should be 5500
The pressure readings on the pressure gauges PSI (6100 PSI on Rubber Track only).
should rise slowly and remain steady when it
reaches the pressure limiter setting. If the Remix Paver Travel Pumps
pressure reading does not change, move the
direction control on the operators console to Each travel motor is driven by a separate pump.
the reverse direction and repeat this step. Each travel pump is made up of a variable
displacement main pump and a charge pump. The
7) Rotate the pressure adjusting screw with the charge pump draws oil from the reservoir and
internal hex wrench, until 5500 PSI (6550 PSI outputs the oil at 295 PSI minimum. The oil is
on Rubber Track only) is reached on the filtered and routed into the intake of the main
pressure gauge. pump. The main pump supplies 5550 PSI
maximum pressure directly to the traction motor. If
Important: Clockwise rotation of the the pressure goes over 5550 PSI the relief valves
pressure adjustment screw will increase the open and bypass fluid to the reservoirs.
pressure setting, counterclockwise rotation
will decrease the pressure setting. Each Travel Drive Systems
complete rotation of the pressure adjusting The travel drive system permits infinitely variable
screw changes the pressure setting by 1350 speed adjustment from zero to maximum with
PSI. torque available for any normal paving load. The
speed will be maintained within the governed
8) While holding the internal hex wrench and
allowance whether the paver is pushing a loaded
pressure adjusting screw in the same position,
truck uphill or emptying the hopper. There will be
tighten the pressure adjusting screw lock nut to
no acceleration downhill even when hooked to a
12 in. lbs. Do not over-torque.
loaded truck.
9) Return the speed dial on the operator console Each travel drive motor is supplied by its own
to zero. The pressure in the high pressure pump, providing independent control of each track/
circuit should return to the charge pressure wheel. The fluid output of the travel drive pumps
setting. To verify the actual pressure setting, can be reversed so the paver can move either
increase the setting on the speed dial while forward or backward without mechanical gear
watching the pressure gauge. The pressure shifting.
should return to the 5500 PSI (6550 PSI on
To move forward the operator places the Travel
Rubber Track only).
Direction Switch or Travel Lever in the forward(F)
position and slowly rotates the Speed Dial
10) Return the speed dial to zero and shut off the
clockwise As the Speed Dial is rotated the Electric
engine.
Displacement Control (EDC) on the travel pump
proportionally increases the angle of the
11) Repeat this procedure to adjust the reverse
swashplate. The increased swashplate angle
circuit pressure. The travel direction control on
the operator console must be moved to the
2) Engage the paver brakes. 6) The pressure gauges should read 0 psi:
3) At the operators console, turn the Paver Speed a) Move the Travel Joy Stick or Switch on the
control to Min., and set the Travel Joy Stick or operators console to the forward direction.
Switch to N (neutral).
b) Slowly increase the setting (cw from Min to
Max) on the Paver Speed control.
NOTICE
High Pressure Relief Valve
The high pressure relief valves are factory
set and should not be tampered with, except
for replacing the entire cartage.
Disassembly of the valve can change the
setting and cause erratic unit operation or
premature failure.
Figure 5 - 18 High Pressure Relief Valves 4) Install a new outer O-ring, new backup ring,
and new inner O-ring on each valve seat plug.
1) Remove the valve seat plugs from the pump
housing. (Figure 5 - 19)
5) Check that the conical springs are properly 3) Install a low pressure line (minimum 500 psi)
retained on the relief valves. Install the high connecting port M4 and port M5. (Figure
pressure relief valve assemblies into the pump 5 - 20) and (Figure 5 - 21) This removes the
housing. effects of any control pressure on the servo
piston.
11) Turn the control neutral adjustment screw ccw, the deliver auger pump proportionally increases the
until the other system pressure gauge starts to angle of the pump swashplate. The increased
increase. This is position B of the internal swashplate angle increases the length of travel for
hex wrench. Note/mark it. (Figure 5 - 22) the pumps pistons which in turn increases the speed
of the deliver auger motors.
12) Rotate the control neutral adjusting screw
clockwise half the distance between location Checking System Relief Setting
A & B. The control should now be in a
The pressure relief valves for spreading auger
neutral position. In this position the gauges
pumps are factory set and should bypass fluid at
should read the same pressure (case pressure.)
3330 +/- 200 psi. The relief valve settings should
(Figure 5 - 22)
not be tampered with, except for replacing the
entire valve. If load reaches this limit, fluid is
13) While holding the control neutral adjustment
bypassed around hydraulic motor and auger will
screw from turning, torque the control neutral
stall. The factory setting is adequate for any paving
lock nut 10 to 18 ft. lbs.
condition. Therefore in the event of a stall, cause of
14) Stop the engine and connect the cable to the overload should be determined and eliminated.
EDC. Remove all pressure gages. Should a relief valve emit a high-pitched squeal,
operator should quickly determine the cause.
Spreading Auger Pumps Continued operation will result in component
damage and operating problems.
Each spreading auger motor is driven by a separate
pump. Each spreading auger pump is made up of a To test the high pressure relief setting:
variable displacement main pump and a charge
pump. The charge pump draws oil from the 1) Stop engine and remove Master key.
reservoir and outputs the oil at 205 PSI minimum.
2) Disconnect high pressure line to the spreading
The oil is filtered and routed into the intake of the
auger hydraulic motor and plug line. (Figure 5
main pump. The main pump supplies 3330 PSI
- 24)
maximum pressure directly to the spreading auger
motor. If the pressure goes over 3330 PSI the relief
valves open and bypass fluid to the reservoirs.
High Pressure Line
Spreading Auger Drive Systems
The spreading auger drive system permits
infinitely variable speed adjustment from zero to
maximum. The feed control system constantly
measures material pile height in front of the screed
Return Line
and adjusts the spreading auger speed to maintain a
consistent level of material in front of the screed.
Pump displacement is controlled by the Electric
Displacement Control (EDC). As the demand for Figure 5 - 24 Spreading Auger Hydraulic Motor
more hot mix at the screed increases, the EDC on
Attach
Pressure
Gauges
High Pressure Relief Valves
Figure 5 - 25 High Pressure Test Ports
Figure 5 - 26 High Pressure Relief Valves
4) Start engine and run at full throttle.
NOTICE
NOTICE
The relief valves are factory set and should
Do not run the pressure over relief any not be tampered with except for replacing
longer than it takes to read the gauge. the entire valve. Disassembly of the valve
can change the setting and cause erratic unit
5) The pressure gauges should read 0 psi. Move operation or premature failure.
the Feed Conveyor Override switch on the
operator console to the OVERRIDE position. System High Pressure Relief Valve
The pressure readings on one of the pressure Replacement
gauges should rise and remain steady when it The high pressure relief valve may be removed for
reaches the pressure limiter setting. If the cleaning and installation of fresh O-rings. (Figure 5
pressure is significantly higher or lower than - 27)
3330 psi, the pressure relief valve is defective
and must be replaced. (Figure 5 - 26) 1) Remove the valve seat plugs from the pump
housing.
Control Neutral
Adjustment
Neutral
Position
Return Line
7) While holding the pump neutral adjustment 12) Rotate the control neutral adjusting screw
screw from turning, torque the pump lock nut clockwise half the distance between location
15 to 19 ft. lbs. (Figure 5 - 29) Stop the A & B. The control should now be in a
engine. neutral position. In this position the gauges
should read the same pressure (case pressure.)
8) Disconnect the Electrical Displacement (Figure 5 - 31)
Control at the pump controller. (Figure 5 - 32)
13) While holding the control neutral adjustment
screw from turning, torque the lock nut 10 to
18 ft. lbs.
Electrical
Displacement
Control 14) Stop the engine and connect the cable to the
EDC. Remove all pressure gages.
9) Loosen control neutral adjustment lock nut 2) Feed Interface Module: Provides a relay
with 17mm wrench and slowly rotate the contact between controller output and
control neutral adjustment screw clockwise, spreading auger pump EDC coil. This relay
with 5mm internal hex wrench, until the pulls in via AUTO-OFF-MANUAL Switch.
pressure is equal on both gages. (Figure 5 - 28)
3) AUTO-OFF-MANUAL Switch: Sends
10) Turn the control neutral adjustment screw: 12 VDC signal to controller to select mode of
operation.
a) First cw, until one system pressure gauge
starts to increase. This is position A of the 4) Ratio Pot: Sends 0.5 - 4.5 VDC signal to
internal hex wrench. Note/mark it. (Figure 5 - controller.
31)
5) Speed Sensor: Located on spreading auger
b) Next, turn the control neutral adjusting motor and provides pulse signal to controller
screw ccw, until the other system pressure to allow AUTO operation.
gauge starts to increase. This is position B of
the internal hex wrench. Note/mark it.
1
3
2
Remix Controllers 6
LH RH
5
4
FEED INTERFACE
MODULE
K3
K4
K5
K6
E
AR
SP
6) Pressure Sensor: Located on rear bulkhead in 3) Pressure sensor on delivery auger motor is
delivery auger motor pressure circuit and active and will limit horsepower when needed.
provides 0.5 - 4.5 VDC to controller indicating
0 to 10,000 PSI of hydraulic pressure. AUTO-OFF-MANUAL Switch in AUTO
a) 0.5 VDC @ 0 PSI
b) 2.5 VDC @ 5000 PSI 1) Ratio dial setting determines the speed of the
c) 4.5 VDC @ 10,000 PSI delivery augers in relation to the spreading
auger speed. (0 - 100% of spreading auger
Remix Delivery Control Operation speed range)
AUTO-OFF-MANUAL Switch in MANUAL 2) Delivery augers start and stop with the
spreading augers no matter what mode the
1) Ratio dial operates strictly as a speed control. spreading augers are operating. (MANUAL,
AUTO, or OVERRIDE)
2) Operates whether spreading augers are ON or
Off. 3) Delivery auger speed is based on spreading
auger speed and ratio setting.
4) Set ratio dial to maintain a uniform head of 1) Controller: Sensor power output wire 284
material (one half auger level). (LH) and 294 (RH) should have 5VDC. If low
voltage, check for defective sensor, ratio pot,
5) Spreading auger RPM should remain constant or grounded wiring.
with this setting.
2) Ratio Pot: Provides range of 0.5 to 4.5VDC to
6) Pressure sensor on delivery auger motor is controller.
active and will limit horsepower when needed. a) 0.5VDC at MIN
b) 2.5VDC at 50% dial setting
Remix Delivery Control Troubleshooting c) 4.5VDC at MAX
The delivery augers are controlled by the remix
3) AUTO-OFF-MANUAL Switch: Provides
feed controllers mounted in the main electrical box.
12VDC to controller to select mode of
(Figure 5 - 33)
operation and supplies power to the controller
If replacement of a controller becomes necessary, eliminating need for feed interface module on
simply remove the old one and plug in the new one. valve output.
No adjustment is needed.
4) Speed Sensor: Located on spreading auger
Refer to the electrical schematic supplied with your
motor, provides pulse signal to controller to
machine and the following information to assist in
allow AUTO operation.
troubleshooting this system. Also, the chart below
(Figure 5 - 34) gives a guide to reading the status of
5) Pressure Sensor: Located on rear bulkhead in
the indicator lights on the controllers.
delivery auger motor pressure circuit, provides
a range of 0.5 to 4.5VDC to controller.
a) 0.5VDC at 0 PSI
b) 0.7VDC at 500 PSI
c) 0.9VDC at 1000 PSI
d) 2.5VDC at 5000 PSI
e) 4.5VDC at 10,000 PSI
Test Port
NOTICE
5) If the pressure gauge does not read 1500 PSI Test Port
loosen the relief valve adjustment. Rotate the
relief valve adjustment until the pressure reads
1500 PSI. Tighten the relief valve adjustment.
REVERSE
SENSING LINES
FROM LH DRIVE MOTOR CASE DRAIN FROM TRACTION
PUMP
SENSING LINES
FROM PARKING
BRAKES
Track Tension
Release Valve
Take-up Valve
Track
Rotated
90 for
Clarity
Pressure
Reducing
Valves Check Valve
Front Accumulator
BTM Port
Adjusting
Screws
ROD Port
Pressure
Reducing
Valves Tension
Release
Cartridge
Test
Front
Ports
4) Shut engine off. Pressure on gauge should not 10) Re-tighten jam nut on tension release valve
change. cartridge.
11) If the pressure is below 1800 psi when it drops 7) If the gauge reading drops off and oil is
quickly to 0 psi, re-charge the accumulator leaking from the check valve, replace the
with dry nitrogen as described in Track check valve.
Tension Accumulator Pre-Charging procedure
in the Paver Technical Manual, then test again. 8) If the gauge reading drops off, no oil is leaking
from the check valve and the tension release
12) If the pressure drops steadily all the way to 0 valve is closed, replace the tension release
psi and re-charging the accumulator does not valve.
work, then replace the accumulator.
9) Re-test as described above until gauge reading
Track Tension Check Valve and Release Valve does not drop off.
Check the operation of the check valve and tension 10) Re-install the hose to the check valve.
release valve on each side.
Track Tensioning Cylinders
1) Install pressure gauge (3000 psi) at test port
marked BTM on the tension release valve Check track tensioning cylinders on each side.
(Figure 5 - 44).
1) With engine off, remove lines from tension
2) Start and run engine at full throttle. release valve to the rod ends of the cylinders
(Figure 5 - 45).
3) Pressure should read 1900 to 2200 psi.
5) If oil is leaking from the cylinder(s) rod ports, 4) With the paver in reverse or stopped, brakes
the cylinder(s) must be repaired or replaced. released, and on level ground, there should be
1900 psi at the BTM port only.
Cap
Fittings
5) Shut the engine off.
Travel Circuit Filters b) Remove the cover from the suction manifold to
gain access to the strainer.
Delivery Auger Filters
Spreading Auger Filters c) Remove the strainer from the suction
manifold. Be careful not to knock
Figure 5 - 49 Charge Filters contaminants off the outside of the strainer as
it is removed from the manifold.
Auxiliary Filter
There is one high pressure auxiliary filter located
on the left side of paver on the front bulkhead. This
Cover
filter consists of filter cap, filter element, and
screw-in bowl. To change filter, remove bowl, O-Ring
replace element and reinstall bowl. (Figure 5 - 50) Strainer
Figure 5 - 50 Auxiliary filter f) Check the condition of the O-ring seal and
replace if damaged.
Solenoid Valves
Solenoid Valves
Solenoid valves mounted on top of each of the
valve banks are controlled by toggle switches on
the operators console. These spool-type valves DIN Connector Cover
direct oil flow to and from the various hydraulic
cylinders which control the paver and screed.
Figure 5 - 52 DIN Connector LED
All of the 4-way, solenoid-operated directional
valves used on the paver are identical units. They If one of the paver functions does not operate, refer
are double-acting valves with spring return of the to the Technical Manual for troubleshooting and
spool to the neutral position. repair information.
Solenoid Valves
DIN Connectors
Override Button
Solenoid Valves
Does the compo- Yes Push the manual A problem exists with
Defective override button on
nent move as it the hydraulic system.
LED the solenoid valve. No
should? See the hydraulic trou-
Does the component bleshooting section in
No move as it should? the Technical Manual.
(Figure 5 - 53)
Yes
Solenoid Valves
Manual Testing of Solenoid Valves the bank is installed. If hoses and ports are not
marked, refer to schematic diagrams for
If the spool cannot be manually shifted or fails to
correct connection details.
return by spring action to the OFF position, the
valve should be completely dismantled, inspected,
3) As each hose is disconnected, plug the end of
cleaned, and tested. If manual shifting succeeds in
the hose and port with a clean plastic plug.
operating the system, try electrical operation again
to see if the coils magnetic force is strong enough 4) Remove the nuts which hold the valve bank to
to consistently move and hold the plunger. the paver and remove the valve bank.
Valve Bank Components valve body and spool off with compressed air.
Reinstall the valve. If it still does not work, replace
Throttle Valve the valve.
The throttle valve allows unrestricted flow in one Flow Control Valve
direction and metered or restricted flow in the
opposite direction. In the case of screed lift, flow in The flow control valve is used in the tow point and
RAISE direction is unrestricted while return flow truck hook cylinders to control the speed at which
in the LOWER direction is restricted by a 3/32 the cylinders move. The valve consists of a valve
diameter orifice. This permits the screed to raise body with a needle valve cartridge.
quickly but to descend at a slower, safe rate. To clean the flow control valve, remove the
A drilled poppet is the only moving part in a cartridge, blow the valve and valve body out with
throttle valve. The valve can be easily inspected for compressed air, and reinstall the cartridge.
presence of foreign matter in orifice. The orifice
can be cleaned using a piece of 1/16 diameter wire Assembling Valve Banks
and compressed air. If probing succeeds in clearing The valve bank should be assembled on a clean
a blockage, the valve should then be flushed clean lint-free shop towel in a clean work area. All
with mineral spirits solvent. These same valves are components should be wiped clean before
used in the hopper wing circuit. assembly. For specific valve bank illustrations,
refer to (Figure 5 - 55), (Figure 5 - 56), and (Figure
Holding Valve 5 - 57).
Holding valves are used on the frame raise, hopper
wings, screed lift, and tow point valve banks. If the 1) Inspect all O-rings before assembly. Replace
engine stalls or a hydraulic line breaks between the any O-rings that are cracked, damaged, dried
pressure source and valve, the holding valve locks out, or not flexible.
the cylinder in its current position to prevent the
screed, hopper wings, etc. from dropping unexpect- 2) Lubricate each O-ring with clean oil or light
edly. When the hydraulic line is repaired and the grease before assembly.
engine is restarted the valve continues to work nor-
mally. 3) Place O-rings in the O-ring recesses . Make
sure O-rings do not get pinched during
assembly.
Solenoid Valve
c) remove the component
The O-rings will leave a circular oil mark on the
mating valve surface. If the component was
installed in the proper orientation the four oil ports
in the mating component surface will be centered
in the four oil marks left by the O-rings. If the oil
marks do not line up with the oil ports, check the
orientation of the component and reinstall.
CAUTION
Valve Block
Throttle Valve
Figure 5 - 55 Frame Raise/Screed Lift Valve Bank
Valve Block
O-ring Spacer
Solenoid Valve
Hold Valve
Needle Valve
Valve Block
Hold Valve
Solenoid Valve
O-ring Spacer
Section 6 - Maintenance
WARNING
Raising the hood
The pavers hood must be raised to gain access to Keep all personnel out from under the hood
the engine for daily maintenance. The hood is until the hood safety latch is engage.
raised using a hydraulic cylinder which is activated Failure to follow these instructions could
by a lever just under the hood on the right side of result in death or serious injury.
the machine in front of the rear wheel or drive
sprocket. (Figure 6 - 1) 3) Verify that the hood safety latch is engaged.
If the paver's batteries become discharged, jumper
Hood Control
cables must be attached to the solenoid next to the
hood raising lever and to the paver frame. (Figure
6 - 2) This will allow the hood raising lever to
function in the normal manner.
Safety Latch
WARNING NOTICE
Keep all personnel out from under the hood Over filling the hydraulic tank does not
until the hood safety latch is engage. leave enough room in the hydraulic system
Failure to follow these instructions could for thermal expansion when the oil is at
result in death or serious injury. running temperature. Excess oil will be
blown out the breathers which could cause
To lower the hood, release the hood safety latch
external radiator clogging.
and activate the hood raising lever. (Figure 6 - 2)
Maintenance Checklist
Maintenance Checklist
Ref. Item to be checked 8 hrs 40 hrs 250 hrs 500 hrs 1000 hrs Yearly As Needed
1 Fuel level I F
2 Fuel Filter / Water Separator D R
3 Hydraulic Fluid I/F R* R
4 Oil Cooler I C
5 Suction Strainers C
6 Charge Filters I R
7 Auxiliary Pump Filter R
8 Hydraulic lines and components I
9 Air Restriction Indicator I
10 Air Filter C/R
11 Engine Oil I/F R
12 Engine Oil Filter R
13 Engine Coolant I/F R
14 Engine Belt I A
15 Radiator I C
16 Engine Cooling Fan I
17 Battery I/F
18 Tire Pressure I/F
19 Frame Raise Eccentric L
20 Steel Track Tension I A
21 Rubber Track Tension I
22 Track Pivot L
23 Fire Extinguisher I
24 Horn I
25 Pump Drive Belts I A
26 Depth Cranks L
27 Vibrator Bearings L
28 Crown Control L
29 Match Height Assembly L
30 Extension Slope Assembly L
31 Final Drive Oil I/F* R
32 Steering Bogie Alignment I/A
33 Steering Linkage L I/A
34 Bogie Beam Bearings L
Key: I - Inspect C - Clean R - Replace A - Adjust
D - Drain L - Lubricate F - Fill * - Initial change only
Table 6 - 1 Maintenance checklist
Periodic Maintenance
Ref. Item to be checked 8 hrs 40 hrs 250 hrs 500 hrs 1000 hrs Yearly As Needed
35 Front Wheel Bearings L
36 Bogie Wheel Toe In I/A
37 Conveyor Slat Chains I/L I/A
38 Conveyor Bearings L
39 DeliveryAuger Clearance I A (Every
120 hrs.)
40 Delivery Auger Drive - Gear Drive I/F* R
41 Front Delivery Auger Bearings L
42 Spreading Auger Bearings L
43 Spreading Auger Drive Chains I/A A
44 Spreading Auger Speed Reducer I/F* R
45 Feeder Drive Chains I A
46 Conveyor Speed Reducer I/F* R
47 Hood Raise Reservoir I
48 Operator Console Pivot Bearings L
49 Tow Arm Nose Roller L
50 Slope Beam Rod Ends L
51 Truck Hitch C/L
52 Fume Recovery System I I C
Key: I - Inspect C - Clean R - Replace A - Adjust
D - Drain L - Lubricate F - Fill * - Initial change only
Table 6 - 1 Maintenance checklist (Continued)
Periodic Maintenance Check fuel level before each work period to ensure
you have enough fuel to operate for the desired
Numerical values assigned to the paragraphs that period of time. Refer to the engine manufacturers
follow directly relate to the numbers in the Ref. manual to determine what grade of fuel to use for
column of (Table 6 - 1), above. your operating temperature and conditions.
Daily Maintenance
WARNING
Drain the water and sediment from the separator
daily. (Figure 6 - 3)
Keep away from sparks or open flame
while working with fuel.
3) Hydraulic Fluid
NOTICE
Separator Drain
Overtightening may distort the treads or
damage the filter element.
Figure 6 - 3 Draining fuel/water separator
4) Oil Cooler
Cover
WARNING O-ring
6) Charge Filters
6) Charge Filters
The paver has two charge filters that protect the
Element
traction hydraulic circuits and two charge filters
that protect the conveyor hydraulic circuits. Each
charge filter is equipped with an indicator that
operates in the green zone when the filter is in good
Bowl
condition and operates in the red zone when the
filter is dirty. The indicators should be checked
every 40 hours with the engine at full throttle. Do
Figure 6 - 6 Auxiliary filter
not wait for the indicator to move into the red zone
before replacing the filters. The filters should be
replaced every 500 hours or when the indicator is 8) Hydraulic lines and components
operating in the red zone, which ever comes first. Check all hoses, tubes, and components for leaks,
(Figure 6 - 5) damage, or loose fittings. Check the ground for
signs of fluid leakage. Spots of oil soaked dust may
WARNING
Figure 6 - 11 Oil Contaminants in Suspension
Do not remove the radiator cap from a hot
Operate the engine until the engine coolant temper- engine. Wait until the temperature is below
ature reaches 60C [140F]. Shut the engine off. 50C [120F] before removing the pressure
Remove the oil drain plug and drain oil into a con- cap. Failure to do so can result in personal
tainer. injury from heated coolant spray or steam.
Remove the filler cap slowly to relieve
coolant system pressure.
CAUTION
(Figure 6 - 15)
OK
Figure 6 - 13 Adding Engine Coolant
OK OK
Figure 6 - 14 Do Not Overfill Radiator
WARNING
15) Radiator
WARNING WARNING
Turn off engine & remove key before Personal injury can result from a fan blade
performing any inspections or failure. Pulling or prying on the fan can
maintenance. damage the fan blade and cause fan failure.
The exterior of the radiator should be checked daily
for dirt and other buildup that would restrict the air
flow. Paving conditions will determine how often
the radiator requires cleaning. If severe conditions WARNING
exist or there are a lot of air-born contaminates the
radiator will require more attention. Any fluid
Turn off engine & remove key before
leaking from any engine compartment component,
performing any inspections or maintenance
hose or tube may find its way into the radiator.
unless specifically instructed to the
When cleaning, check between the radiator and
contrary in this manual.
other components for buildup.
A visual inspection of the cooling fan is required
Check for damaged hoses and loose or damaged
daily. Check for cracks and bent or loose blades.
hose clamps. (Figure 6 - 17) Replace as required.
Check the fan to make sure it is securely mounted.
Check the radiator for leaks in the upper and lower
Tighten the bolts if necessary. Replace any fan that
radiator sections. Check the radiator core for
is damaged.
damaged or bent fins. Clean and repair as required.
OK OK
OK
OK
OK
17) Battery
17) Battery
The battery fluid level should be checked to ensure CAUTION
it is at the correct level.
When removing the battery cables, always
remove the negative terminal first then the
WARNING positive terminal. This will reduce the
chance of sparking.
Do Not allow open flames or sparks near The battery terminals should be checked for
batteries. Battery fumes are highly corrosion buildup and tightness of connection. If
explosive. necessary remove the terminal cable and clean both
the battery cable connector and the battery
terminal. Reinstall the positive battery cable
WARNING connector first then the negative and tighten
securely. Loose or corroded connections are a
Sulfuric acid in batteries is a poison and prime source of starting problems and other
could cause severe burns. Avoid contact electrical problems.
with skin, eyes, and clothes. When you
work around batteries, protect eyes and face Cleaning Batteries
from battery fluid and explosion. Make sure all the battery caps are on tight before
cleaning the battery. Allowing dirt or baking soda
Checking battery fluid levels solution into the battery will destroy the battery.
The battery fluid level should be checked to ensure Batteries should be kept clean at all times. Wipe the
it is at the correct level. If necessary fill the battery outside of the battery with a cloth to remove dirt
with clean water to bring the fluid level up to the and grime.
bottom of the neck of each battery cell. (Figure 6 -
18) Make sure the vent holes in the battery caps are
kept open at all times to allow gas to escape from
inside the battery.
To clean the battery cable and terminals, remove
the battery cables and clean them with a wire brush.
Soak the cables and wash the terminals in a
solution of baking soda and water. Rinse the
cables, battery, and battery compartment with
clean water.
18)Tire Pressure
Under normal temperature conditions, a fully Apply Loctite 272 to threads of lug nuts. Torque
charged battery will have a corrected specific lug nuts to 267 ft.-lbs.
gravity reading of 1.26. If the reading is below 1.2,
the battery should be charged. 19) Frame Raise Eccentric
In very warm weather the full charged reading The paver frame raise eccentric should be greased
should be 1.225. In very cold weather the full every 500 hours of operation. (Figure 6 - 19)
charged reading should be 1.28.
Some frame raise eccentric plain bearings were
If a battery becomes drained and has a specific assembled with Dow Corning G-N Metal
gravity reading below 1.15, jump starting the Assembly Paste (P/N 49999-222) and had pipe
engine will put a heavy load on the battery and the plugs installed instead of grease fittings.
charging system which could damage the
alternator. If the specific gravity reading is below If a plain bearing is disassembled, re-assemble with
1.15, charge the battery before using it to start the Dow Corning G-N Metal Assembly Paste (P/N
engine. 49999-222).
If any frame raise eccentric bearing has pipe plugs,
Storing Batteries remove them, install grease fittings and grease at
If the paver will be stored for more than 30 days, the 500 hour interval.
remove the batter. Make sure the battery is full
charged and store the battery in a cool place.
When the battery is stored outside of the paver or
while the battery is being charged, never set the
battery on a concrete or dirt floor. The battery
should be placed on wooden blocks.
18)Tire Pressure
Tire pressure for all paver tires should be
maintained at 32 psi. The drive tires can be filled
with calcium chloride and water in accordance with
Table 6 - 2, if necessary, for operational conditions.
This capacity puts tires to 75% full.
Grease Fittings
Eccentric with Roller Bearing
20) Steel Track Tension gap between the bottom of the board and the top
edge of the track is greater than 3/4, the track
The track tension on Track Pavers can be adjusted tension must be adjusted. (Figure 6 - 20)
to provide the desired track tension. The track has
an automatic recoil system that allows the tracks to
recoil if an impact is encountered then return to NOTICE
previous adjustment point.
Perform track tension checks and
Checking steel track tension adjustments when the paver is at operating
Set the brake switch to ON, travel lever/switch to temperature. Adjusting track tension when
NEUTRAL and speed dial to MIN (0) before the paver is cold could lead to over-
performing checks. tensioning of the track.
The Track Paver uses a tension cylinder mounted Steel Track over-pressurizing
above the final drive that maintains a constant
If the track adjusting system is over-pressurizing
volume of pressurized oil to the track adjusting
during operation the following procedure must be
cylinders. When the track encounters an obstacle,
performed. It is a good idea to perform this check
the system is designed to allow the tensioning idler
once each season to verify the tensioning cylinder
to recoil, rather than stretch or break the track.
is in good condition.
When the obstacle is cleared the system returns to
the previous track tension adjustment.
The track tensioning cylinder consists of a cylinder
with a rodless piston, a needle valve, and a NOTICE
counterbalance valve. (Figure 6 - 21) The piston
keeps the oil from the idler tensioning cylinders Do not run the paver while the system is
separated from the main oil supply. When the track over-pressurized. Running with an over-
encounters an obstacle it forces oil from the idler pressurized system could damage the track
cylinders into the bottom side of the tensioning and sprockets.
cylinder. When the obstruction is cleared,
pressurized oil from the traction charge pump 1) Disconnect the line from the T port on the
forces the tensioning cylinder down which forces track tension cylinder. Install a plug into the
the idler cylinders to move back to the original disconnected line. (Figure 6 - 22)
position.
T S
1 T Port
3
4 Needle
Valve
5) If the track was tensioned properly, no oil will 21) Rubber Track Tension
flow into the bucket.
The tracks on Rubber-Track Pavers (Figure 6 - 23)
6) If only a small amount of oil drains into the do not require periodic adjustment. They are self-
bucket, the piston and counterbalance valve are adjusted by applying a pre-set hydraulic pressure
working properly and the track will be supplied by the auxiliary pump to the tensioning
properly tensioned. cylinders. The tracks have an automatic system that
allows them to recoil and return to tension if a
7) If oil continues to flow into the bucket, the severe impact is encountered. If tracks appear
piston or counterbalance valve is leaking and loose, troubleshoot the track hydraulic system (see
must be repaired. Section 5).
23) Fire Extinguisher Turn off engine & remove key before
performing any inspections or
The fire extinguisher should be inspected every maintenance.
250 hours to ensure the extinguisher is fully
charged and has not been damaged.
Large O-ring
NOTICE
Figure 6 - 26 Tester Used Correctly (top view) Figure 6 - 28 Tester Used Incorrectly
Press Downward
NOTICE
30
Check poly chain belt tension only after the
25
20
15
10 entire machine is at operating temperature
Tension (Lbs)
5
Grease Fittings
Grease Fitting
31) Final Drive Oil 80W-90, Exxon Gear Oil GX 80W-90, Shell
Spirax HD 80W-90. An ISO Grade 150 EP oil can
The final drive planetary oil level should be be substituted for those given above.
checked during the first 40 hours of operation and
replaced at 150 hours of operation. Drain, flush and
refill every 1000 hours of normal operation. 32) Steering Bogie Alignment
To check the oil level, rotate the drive until the fill It is normal for the bogie wheel to get slightly out
plug is straight up and the level check plug is 90 of alignment during normal operation. Driving
degrees down from the fill plug. Remove the level with misaligned bogie wheels can make steering
check plug. The oil level should be even with the difficult and increase wear of the bogie tire. (Figure
bottom of the level check plug hole. If the oil level 6 - 34)
is low remove the fill plug and add oil to bring the
level up to the bottom of the level check plug hole.
(Figure 6 - 33)
NOTICE
Angled Out Normal
Angled In
Alignment
Verify there is no hydraulic oil in the final
drive housing before adding gear oil. Figure 6 - 34 Bogie Wheel Alignment
Hydraulic oil in this housing indicates
leakage from the brake or hydraulic drive If the bogie wheels are angled in or out the wheels
motor. will need to be realigned. Realigning the bogie
wheels is accomplished without the use of any
Fill Plug tools and can be performed any time the paver is
parked.
Level To synchronize the steering bogies:
Check
Plug
1) Stop the paver and run the engine at full
throttle.
Lubricate
Direction of Travel
X + 1/16" to 1/8"
Locking Rod
Dual Adjuster
Figure 6 - 38 Conveyor Chain Adjuster
Figure 6 - 39 Front Conveyor Fittings
5) Using the locking rod or a wrench, rotate the
left adjuster 1/2 turn.
Drive
Retaining Retaining Bolts
Bolts 4 - Each Auger
Retaining Bolts
4 - Each Auger
Drive
Retaining
Bolts Figure 6 - 43 Setting Auger to Liner Spacing
40) Delivery Auger Drive - Gear Drive 41) Front Delivery Auger Bearings
Each delivery auger gear drive speed reducer oil The front delivery auger bearing on each of the four
level should be checked every 40 hours and augers should be lubricated every 8 hours of
replaced every 1000 hours of operation. The oil is operation with Lithium base, type EP, Grade 2
at the correct level when the oil is just above the grease. (Figure 6 - 45)
sight glass (check at style A or B). (Figure 6 - 44)
Front
Use 80W-90 gear oil in the speed reducer. Typical Auger
brands: Amoco Multipurpose gear Lube 80W-90, Bearing
Texaco Multipurpose Gear Lube 80W-90, Fittings
Mobilube HD 80W-90, Exxon Gear Oil GX 80W-
90, Shell Spirax HD 80W-90. An ISO Grade 150
EP oil can be substituted for those given above.
Breather/Fill
Plug
Sight
Glass
Inner
Auger
Bearing
Outer
Auger
Bearing
Drain
Plugs
Figure 6 - 46 Spreading Auger Bearings
Figure 6 - 44 Delivery Auger Drive
Gear Drive
43) Spreading Auger Drive Chains 15) Using the adjuster rods, remove the slack from
the chain, but do not over tighten. At the
The spreading auger drive chains should be correct tension, the chain should move slightly
checked every 40 hours of operation. Check the under thumb pressure.
drive chains for proper tension and wear. Check the
bronze spacer washer between the auger drive 16) After both chains have been tensioned
sprockets for wear. Clean the housing and lubricate properly, tighten the jam nuts. Replace the
the chains and spacer with fuel oil from the spray- cover.
down hose or with SAE 10 motor oil. A small
amount of oil may be left in the housing for
lubrication between checks even though the
44)Spreading Auger Speed Reducer
housing is not oil tight.
WARNING
WARNING
Turn off engine & remove key before
Turn off engine & remove key before performing the following inspections or
performing the following inspections or maintenance.
maintenance. The spreading auger speed reducer oil level should
be checked in the first 40 hours and replaced every
13) Remove the cap screws holding the spreading 1000 hours of operation. The oil is at the correct
auger drive chain cover. Pull the cover back level when the oil is level with the bottom threads
and off. (Figure 6 - 47) of the level check plug. (Figure 6 - 48)
Adjuster Rods
Remove
Chain
Cover
Drain Plug
Drain Plug
Fume Recovery System Repair a) Disconnect tubes from left and right hoods
and to muffler.
1) Check hoses and tubes for cracks, cuts, dents,
or collapsed spots. Cuts or cracks may be b) Disconnect hose to vacuum indicator.
repairable with duct tape. Repair or replace
tubes as needed (Figure 6 - 55). c) Remove four bolts retaining inlet manifold
to fan assembly and remove inlet manifold.
2) Check interior surfaces of hoses and tubes for
asphalt buildup. Clean tubes and hoses by d) Lift off fan housing.
soaking in solvent and brushing clean. Hoses
and tubes may be more economically replaced e) Remove bolt and two washers retaining fan
than cleaned. wheel to motor shaft.
3) Disassemble the fan for cleaning using the f) Remove fan plate by removing four bolts.
following procedure (Figure 6 - 56):
5
6
5 1
4) The parts removed in the previous step can all 5) Reassemble fan in reverse order. When
be cleaned by soaking in solvent and cleaning installing fan wheel, use Loctite 242 on the
with a brush. bolt and torque to 110 in-lb.
NOTICE
Fan Housing
Fan Plate
Inlet Manifold
Corrective Maintenance
Corrective Maintenance
3
Steel Track 1
4
5
The track is designed to be virtually maintenance
free. Proper cleaning and lubrication at the end of
each paving day will maintain trouble free S T
operation. However, neglect of the tracks can be
expensive. Every time paver is cleaned, the track
2
pins should be sprayed with light oil to lubricate
them preventing them from rusting and binding.
1 - Counterbalance valve 4 - Needle valve
The track paver uses a tension cylinder mounted 2 - Rodless piston cylinder 5 - Idler tension cylinders
above the final drive that maintains a constant 3 - Tensioning cylinder assy.
volume of pressurized oil to the track adjusting Figure 6 - 57 Track tension hydraulic circuit
cylinders. When the track encounters an obstacle,
the system allows the tensioning idler to recoil Steel Track Tensioning
rather than stretch or break the track. When the If the track looks like it may be getting loose, it can
obstacle is cleared the system returns to the be tested by placing a board or straight edge on the
previous track tension adjustment. track between the front idler and the first top roller.
The track tensioning cylinder assembly consists of If the gap between the bottom of the board and the
a cylinder with a rodless piston, a needle valve, and top edge of the track is greater than 3/4, the track
a counterbalance valve. (Figure 6 - 21) The piston tension must be adjusted. (Figure 6 - 58)
keeps the oil from the idler tensioning cylinders
3/4
separated from the main oil supply. When the track
encounters an obstacle, it forces oil from the idler
cylinders into the bottom side of the rodless
cylinder. When the obstruction is cleared,
pressurized oil from the traction charge pump
forces the tensioning cylinder down which forces Figure 6 - 58 Checking track tension
idler cylinders to move back to original position.
The needle valve is used during track tensioning to
bring the volume of oil on the bottom side of the NOTICE
rodless cylinder back to the proper level. The
counterbalance valve allows oil to flow freely from Perform track tension checks and
the top side of the rodless cylinder to the tank when adjustments when the paver is at running
the track encounters an obstacle. temperature. Adjusting track tension when
the paver is cold could lead to over-
tensioning of the track.
Adjust track tension as follows:
Steel Track
Be very careful when reaching over the 1) Disconnect the line from the T port on the
moving track. Keep feet and loose clothing track tension cylinder. Install a plug into the
away from the moving track and rollers. disconnected line. (Figure 6 - 60)
4) Stop the paver and close needle valve. 2) Attach a drain line to the T port and run the
other end into a bucket.
5) A properly tensioned track should have a 3/8
to 1/2 gap between a straightedge and the 3) Close the needle valve by rotating clockwise.
track. (Figure 6 - 59)
4) Start the engine and run at full throttle.
3/8 to 1/2
5) If the track was tensioned properly, no oil will
flow into the bucket.
WARNING
T S
T Port
Overtightening the track can cause serious
damage to the track, idler or drive. Needle
Valve
Steel Track
7) If oil continues to flow into the bucket, the 3) Place boards between the sprocket and upper
piston or counterbalance valve is leaking and roller as shown. This elevates the track
must be repaired. allowing it to clear the upper roller while
driving the track toward the idler. (Figure 6 -
8) Turn the engine off and reconnect the 61)
hydraulic line to the T port.
Upper Roller
Steel Track Relief Pressure
In addition to adjusting the track tension, the track
relief pressure should be checked at least once each
season. Refer to the Paver Technical Manual for
information on checking track relief pressure.
Figure 6 - 61 Place board between sprocket and roller
Steel Track Installation
4) Place the track under the paver with the end of
the track marked OPEN positioned on the
WARNING sprocket as shown and the other end stretched
out in front of paver. (Figure 6 - 62)
Steel Track
Come-a-long
Figure 6 - 64 Pull track ends together To remove the track assembly, perform Track
Installation procedures in reverse order.
8) Remove paint from interlocking ribs of master
link and lightly grease contact surfaces. Clean Replacing Steel Track Drive Sprockets
bolt holes and threads, and apply anti-seize or When sprocket teeth are worn, the sprocket can be
grease to track shoe bolts. replaced or turned around to restore sprocket teeth
to new condition. Perform the following procedure
9) Connect the ends of the track by mating the
if sprocket replacement is necessary.
two halves of the master link. (Figure 6 - 65)
1) Rotate the track until the master link is
Track Pad
Master Link positioned on the sprocket.
NOTICE
Steel Track
NOTICE
The cylinders on the 500 Series frame raise 1) Remove the bolt retaining the bushing to the
mechanism are held in place on the top by a frame. (Figure 6 - 70)
bushing. A special tool, P/N 9704-800-31, has been
designed to simplify the process of removing these
bushings. (Figure 6 - 69)
Rubber Track
Rubber Track
WARNING
1) Shut off engine and remove key from ignition. 6) Remove porta-power.
2) Loosen jam nut on tension release valve 7) Jack up track frame until the track will slide
cartridge (Figure 6 - 76). out from under the bogies. Support paver with
blocking capable of supporting its entire
weight.
Rubber Track
Rubber Track
Un-bolt
Rod Here
Pull Arm
Un-bolt
Un-bolt Cylinder
Pull Assembly
Arm Here
Here
Rubber Track
NOTICE
Rubber Track
NOTICE
Rubber Track
1 - Bogie Frame
2 - N/A
3 - Bogie Wheel
4 - Inner Bearing Cone
5 - Inner Bearing Cup
6 - Outer Bearing Cone
7 - Outer Bearing Cup
8 - Shaft Seal
9 - Washer, Keyed Flat
10- Washer, Bearing Lock
11- Bearing Nut
12- Grease Cap
10) Loosen bearing nut until it is finger tight. 14) Install grease cap (12) into bogie wheel
housing.
Repeat steps 1 through 14 above for each bogie
wheel.
Rubber Track
4
1
Rubber Track
Head
Nut
Rubber Track
Rubber Track
9) Install two cap screws (18) 180 from each 17) If this torque value is not achieved, repeat steps
other and tighten in 90 increments. As the two 9 through 16.
cap screws are tightened, keep the others
finger tight to prevent the bearing cap from Assembly
flexing as it puts pressure on the bearings.
Refer to (Figure 6 - 82) and the following
procedure to re-assemble the front idler assembly
10) While turning the shaft with a torque wrench,
after bearing replacement:
continue the tightening until a sudden rapid
rise in the torque is seen, then stop.
15) Remove the bearing cap, install the shim stack, 4) Install slider blocks (6) through side plates and
and re-assemble tightening all cap screws to onto shaft (5) aligning each roll pin hole in
specified torques. block with hole in shaft.
16) Rotate the shaft, measure and record the 5) Install roll pins (12) into slider blocks and
rolling torque once again. This torque value drive through holes in shaft until flush with
should be 20 to 55 in/lb greater than the edge of blocks.
baseline rolling torque recorded in step 11.
6) Rotate, if necessary, slider blocks to align cap
screw holes with holes in side plates.
Slat Conveyor Paver, Slat Conveyors 9) Reinstall all parts by reversing the disassembly
procedure and perform the Slat Conveyor
Replacing Slat Conveyor Liners Tensioning procedure.
4) Remove outer rear and inner rear skirt boards. Remix Paver Delivery Augers
5) Loosen slat conveyor chain take-ups.
Replacing Auger Liners
6) Remove pin from chain link and break each Liners are bolted to the hopper bed to provide a
chain at a point just below the rear drive wearing surface over which the mix is carried.
sprockets. Inspect and replace auger liners as needed.
7) Pull the top section of each slat conveyor 1) Detach screed from tractor. Make sure all
forward through the hopper. Place slat electrical cables and hydraulic hoses are
conveyors on the ground in front of the paver. disconnected before pulling tractor away
The return portion of each conveyor (underside (Refer to Screed Section of this manual).
of paver) need not be moved unless the slats
and chains are to be inverted. 2) Elevate the paver to allow an adequate amount
of safe working space under the tractor so the
8) Unbolt and replace all liner panels which are liner nuts can be reached. Support the paver
worn out. with blocking equipment capable of
supporting the weight of the paver.
Liner Panels
Torque Charts
Torque Charts
The following pages contain charts for use as
guides when tightening bolts and nuts. These
specifications should be followed unless specific
torques are given elsewhere in this manual.
Standard Torque Chart
Table A - 1 is a list of recommended torque values
for standard bolts. Use this torque chart to avoid
overstressing standard nuts and bolts used on
Cedarapids equipment. These specifications should
be followed unless specific torques are given.
Cedarapids uses Grades 2, 5, and 8. The maximum
torque values are based on 75% of the specified
minimum proof strength of the bolt steel in order to
provide a safety factor. The term lube applies to
cadmium plating and/or application of thread
lubricants. Hardened washers should always be
used, regardless of whether standard nuts or lock
nuts are employed.
Metric Torque Chart
Table A - 2 is a list of torque values recommended
for metric bolts. The maximum torque values are
based on 75% of the specified minimum proof
strength. The term lube includes the application
of thread lubricants, cadmium plating and the use
of hardened washers regardless of whether
standard or lock nuts are used.
Torque Charts
Torque Charts
Torque Charts
Electrical Schematics
Electrical Schematics
The following pages contain The electrical
schematics for the various configurations of the
500 Series Pavers
Electrical Schematics
3 RANGE
TRAVEL
12 V.D.C.
STARTER 46
P/2
1 1 3 27 3
FWD SOL.
P/4
K2 42 3
100 100 2 3 RANGE SOL.
46
ENGINE
ENGINE E-STOP STOP BRAKE DIFF. LOCK
L.S.3 OFF
1 20 21 17 ENG 14 15 3 46A 79 3
RUN K2 LOCK SOL.
15A. 13 CLOSED IN NEUTRAL ON
MAIN (TRAVEL CONTROL)
START REL STARTER RELAY
KEYSWITCH
A STEER ASSIST
L
17 3 STEER
K1 46A 79
ASSIST
STOP R MODULE
POWER RELAY
46065-500-34
17 RUN 22 75
75
ALTERNATOR 46A
START 76
R 11 76
3
S HOUR/TACHOMETER
22 3
B I G
1
H/T 73A
73A 73 3
23 PIN 74A R
5A 74A A B LH
A TRACTION
73 74 3 EDC
B F
74 D C
7.5A
C
77 77 3
7.5A D R
78 A B RH
3 TRACTION
E
7.5A 3 78 3 EDC
F F
D C
74A
G
3 73A
H
3
BRAKE
J ENGAGE
1 REMIX
2 46 34 34 3
ONLY BRAKE RELEASE SOL.
K HYD DUMP RELEASE
10A TO 'A'
L TRAVEL
COOLING STARTING CONTROL
M FAN CIRCUIT HANDLE
3 14
N
1 2 N
O 15 RED MAX
3 PAVER
P SPEED
10A N
1K Q
Q
3 RED WHT CW
W B
BLK
TRAVEL C
WATER TEMP.
SPEED RED
WT A
22 7 3 CONTROL
I S MODULE
G WHT BLK 3 3
D
OIL PRESS. RED 34
OP C
22 8 3
I S R GRN 73A
G B
F WHT 74A
NOTE:
OIL TEMP. A
OT
22 9 3
I S R 49 49 3
G
F 47
BACKUP ALARM
LH (OPTIONAL)
10L TANK 3
FUEL LEVEL A VIBRATORS
QSB STOP FUEL OFF
22 10 47 47 47 50 3
5 I S B
HOPPER RAISE 65 3
THROTTLE 'RAISE' SOL.
48 46 WINGS
2200 RPM B28 FULL
3 LOWER 66 3
IDLE 'LOWER' SOL.
GENERATOR
OFF REAR RAISE 70 3
21B 3 'RAISE' SOL.
1400 RPM B47 46 FRAME
ON
LOWER 71 3
45 21A 'LOWER' SOL.
OPTION
WIF SENSOR 3
B40 LH RAISE 103 3
K15
(LOCATED IN GATE
46
FUEL FILTER)
GRID HTR RELAYS LOWER 104 3
K16
B41 BATTERY + 1
RH RAISE 107 3
6 AWG K17
125A FUSE + - 46 GATE
TWIN
GRID LOWER 108 3
K18
BATTERY + 1 HEATER
B31
UNIT
6 AWG
125A FUSE + -
LIGHTS
K5
4 109A 110 110 110
ENGINE BLOCK
GROUND 3 25A. HEAD
LGTS. WORK
W W W W
LGTS.
DIAGNOSTIC
TWISTED 3
J1587 PUBLIC DATA LINK(+)
B49 F
J1587 PUBLIC DATA LINK(-)
B50 G FLASHERS STROBE
23030 (7/03)
K6
5A 4 113A 114 114 3
1 BATTERY +
4494-105-21
B A
3 15A.
A
J1939 +
C
1 J1939 J1939 -
K1 TO D
B- 3
ENGINE J1939 SH
4
E
VENT
HYD VENT VALVE
5A 3
Page 1 of 4
452/552 Paver
4
1 2
Electrical Schematic
CONSOLE
4 46
15A.
9704-417-36, 9704-417-55, 9704-417-54
100
4/03
4 3 46 47 3
CONTINUED TO PAGE 2 OF SCHEMATIC
500 Series Pavers
Electrical Schematics
23030 (7/03)
CONTINUED FROM PAGE 1 OF SCHEMATIC
B- 4
100 4 3 46 47 3
HORN
GENERATION III
GATES
K3 LH CONVEYOR CONTROL
4 100 19 19 3
FEEDER
30A. A A A +14V CONTROL +14V A
HORN SW. SONIC
100 18 18 3
K3 B B B GND GND B
K17 REMOTE
100 105 YEL RED 106 3
FEED
OVERRIDE 52
105 3 45
STOP
LH FLOW MATERIAL FLOW INDICATORS C
F/G/S SWITCH LH NO FLOW
AND FLOW ALARM RELAY
4 245 (A) (B) 88 88 3
R LH FEED
15A. (C) OVERRIDE 52
OPENS WITH 46 46
3 OFF
MATERIAL CRFA
PRESENT 89 3 AUTO
46
RH FLOW 51
SWITCH RH NO FLOW
(A) (B) 98 98 3
R 51
(C) 12 LH
52 C
11 87 3 FEED
OPENS WITH 3 EDC
83 83 A B
MATERIAL 10
PRESENT 81 81
47 9 STOP
FEED 80 80
INTERFACE 8
MODULE 3 3
7
SCREED 47
6
4 45 90
5 RH
91 D
15A. 4 97 3 FEED
93 93 EDC
LH AUTOMATIC SCREED CONTROL 3 A B
NOTE:
MAT THICKNESS 54
WIRE 45 2
SAME AS (TOWPOINT) STOP
47 53
46 ON AUTO 1
SCREED
ONLY! SET LH AUTO ISOLATION RELAY 47
45 152 8 1 3
MAN LAI
152 REMOTE
155 FEED
INC OVERRIDE 54
150 150 45
45 157
DEC
STOP
D
3 3
A
45
B
155A RH FEED
C INC. SOL. OVERRIDE 54
157A 155A 4 3 3
155 46
D OFF
155A
E DEC. SOL.
157A 157A 157 3 AUTO
F
5 6
G 46
53
H 91
J 46 46 3
A WAND
RH AUTOMATIC SCREED CONTROL 5 PIN B 1KQ
MAT THICKNESS E B D C 1/2W.
C
47 (TOWPOINT)
AUTO D
10 PIN
SET RH AUTO ISOLATION RELAY B D C A E
45 162 8 1 3 5 PIN FEEDER
MAN RAI
A +14V CONTROL` +14V A A A
162 SONIC
B GND GND B B B
165
INC
C +8V GND C C C
160 160
45 D SIG. SIG. D D
167
DEC
E GND +8V E E
3 3
A
45 GENERATION III
B
165A
C INC. SOL.
167A 165A 4 3 3
165
D
167A
E DEC. SOL.
165A 167A 167 3
F
5 6
G
H
I 10 PIN RECEPTACLE FOR AUTO CABLE
J
SCREED CONTROLS
INC. SOL.
LH INCREASE 171 3
45 SLOPE
DEC. SOL.
DECREASE 172 3
INC. SOL.
RH INCREASE 181 3
45 SLOPE
DEC. SOL.
DECREASE 182 3
46
RH CONVEYOR CONTROL
IN SOL.
LH IN 173 3
OPTIONAL FOR NON-FUEL OIL HEATING 45 EXTEND
OUT SOL.
SPRAYDOWN JUMPER FUEL PUMP OUT 174 3
FUEL PUMP MOTOR
NOTE:
OFF
4 117A 117 117 3 LH EXT.
IN 173
ON (CONSOLE)
15A. 46
STANDARD FUEL OIL BURNER CONTROL OUT 174
BURNER FUEL PUMP
OFF FUEL PUMP MOTOR
4 115 117 117 3
IN SOL.
50A. ON RH IN 183 3
FAN NO.1 LH MAIN BURNER (NO.1) 45 EXTEND
OFF FAN MOTOR NO.1 OUT SOL.
115 116 116 3 OUT 184 3
4494-105-21
ON RH EXT
GLOW PLUG NO.1 IN 183
GLOW PLUG NO.1 (CONSOLE)
115 118 118 3 46
OUT 184
MATCH UP 185 3
115 138 138 3
45 HEIGHT
DOWN SOL.
DOWN 186 3
FAN NO.4 RH EXT. BURNER (NO.4)
OFF FAN MOTOR NO.4
115 146 146 3
INC. SOL.
ON MAIN INCREASE 189 3
GLOW PLUG NO.4
9704-417-36, 9704-417-55, 9704-417-54
ITEM LBS/PIECE PART NO./ PATTERN NO. DESCRIPTION QTY ITEM LBS/PIECE PART NO./PATTERN NO. DESCRIPTION REQ.
46A
79
79
51 52 54 53 22 13 50 63 33 79
28
46 46
22
17 47 47 46 64 46A
51 07014-005 LOCK WASHER- 1/2" 2 6 46015-001-24 SNAPTRACK-PVC 1
51 53 89C 64
76
75
S2 S4 52 07455-012 SHOULDER SCREW- 3/8" X 5/8" 2 7 09704-416-36 POTENTMTR-SPEED 1
47
183
174
184
173
46
46
35
29
37 70
49 53 07012-024 HEX NUT- 5/16"NC 2 8 46075-500-05 KNOB-1"DIA 1
3 3 46
22
36 71 54 07014-002 LOCK WASHER- 5/16" 2 9 09704-411-34 CABLE-LH 1
14
S1 S3
NOTE: 55 46085-401-46 E-STOP- MUSHROOM BUTTON 1 10 09704-411-35 CABLE-RH 1
104 108 15
30
113 DRILL 1/2" DIA HOLE LINED UP
46 46
22
22 18 56 END BARRIER AB #1492-EB3 2 11 45865-002-41 GAUGE-OIL PRESSURE 1
ON CENTER LINE OF FUEL GAUGE
103 107
AND 1" FROM TOP EDGE 57 RAIL- AB #199DR1 24" 12 45865-003-16 GAUGE- OIL TEMP 1
34
65 61
6
109 42 3 3 58 TERM. GND AB # 1492-WG4 4 13 45865-003-17 GAUGE- WATER TEMP 1
46 46 22 46 13 46 48 18
22
66 62 27 46A 14 59 46260-005-32 MARKER AB #1492-SM6-12 (100/CARD) .8 14 45915-012-08 GAUGE- FUEL LEVEL 1
7
60 04494-105-11 EMBLEM- FUEL SELECT 1 15 46225-001-24 METER- VOLTMETER 12VDC 1
89C
3 3 5
22
89B 22 I S 61 46955-001-43 DIODE-600V 6A 2 16 46225-010-17 METER-TACH/HOUR 1
88 98 3 G
22 I S 11
62 17 TERM- AB #1492-W4 74
3 G 22
3 3
29 46270-005-09 LIGHT KIT- METER 5
ALARM
3A 61 LH-NO FLOW-RH STOP
ON WATER
30 46270-005-10 LIGHT KIT-12VDC 1
3C 62 TEMPERATURE
5 63
6 64
7 65 22
8
9
66
70
OFF 31 46270-002-44 LAMP- 14VDC 7
10 71
27
11
15
73
74
HOPPER
RAISE
TRUCK HITCH
ENGAGE
WARNING
LIGHTS
ON 20
RANGE
TRAVEL RELEASE
BRAKE THROTTLE
FULL
HORN
2 32 46270-500-36 LENS- RED #30100/PILOT/JLR 1
17 77
18 78
21 79
P/2
33 46061-500-62 SOCKET 7
21A 103
LOWER RELEASE OFF P/4 ENGAGE IDLE
22 104
24
25
107
108 24 4 34 46010-001-29 ALARM- SIGNAL 1
27 109 6 LH - REMIX - RH
MAINTENANCE
FLASHER
MAN ON 23 20
28
29
113
173
20 35 46270-500-37 LENS- AMBER #30106/PILOT/JLA 6
30 174 OFF
33 183 24
34
35
184
284
AUTO OFF 36 46275-001-02 WIRE LUG-14/16 EYE 5
36 285 PAVER SPEED
WATER IN SCREED EXTENSION REAR FRAME
37 07437-135 MACH SCREW-1/4"NC X 3/4" 2
STEER ASSIST
37 286 ASSIST BYPASS ENGINE DIAGNOSTIC 4
5
6 F
46065-500-34
FUEL
42 294 75
D1 D2 24 ON INC. LH RH RAISE
3 7
46 295 76
3
47 296
48 331
OUT IN OUT 2 8 N
38 46026-015-14 CONNECTOR- 1 1/4" 90 DEG 2
49 332 73A 73A OFF 1 9
KL KR DEC LOWER
50 SP3 74A 74A
51
52
SP2
SP1
73
74
73
74
WAIT TO VIBRATORS SCREED LIFT SCREED ASSIST
MIN. MAX. R
39 46195-001-04 LOCKNUT 1 1/4" 2
LH - FEED - RH ENGINE DIFF.
53 88 START LOCK
78 R1 R2 78 OVERRIDE START ON RAISE ON STEER ASSIST
89
40 45890-100-06 SEAL NUT- 3/8"NEF X 32 28 1
54 77
ENGAGE
77
98 ONLY
WHEN
3 3 3 OFF
SCREED
89A IS ON
+ AUTO STOP OFF LOWER GROUND OFF 41 45890-100-29 NUT- 1/4" SELF RETAINING 2
42 45890-800-31 EDGING- 1/16"-B-2-ALUM 4.7'
43 07504-066 MACH SCREW- #10-32 X 1/2" 2
20 25 20 22 24
25 26 8 44 07504-52 MACH SCREW- #8-32 X 1/2" U 4
5 40
89A 34 28 45 07438-023 WASHER- #10 SHKP LK 2
89
43 45 47
3
NOTES:
4494-105-21 Page 3 of 4 4/03
1. MOUNT ALL SWITCHES WITH KEYWAY TOWARDS HINGE, EXCEPT:
89B PERMISSIVE START, SCREED ASSIST, VIBRATORS, 452/552 Paver
2. SPRAY ALL CONNECTIONS WITH PERMATEX "FORM-A-SEAL" Electrical Schematic
CRFA 3. MARK CONSOLE ASSEMBLY WITH APPROPRIATE PART NO. AND REV.
9704-417-36, 9704-417-55, 9704-417-54
C D
ENGINE
MEGA
125A 2 2
3A 3A
3C 3C
HEAT
GRID
5 5
6 6
7 7
8 8
9 9
10 10
11 11
15 15
17 17
MEGA 18 18
125A 19 19
21 21
21A 21A POWER
21B 21B 15 15 15 15 15 15 15 30 50
22 22 ON
24 24 ENGINE SCREED CONSOLE F/G/S SPRAYDOWN LIGHTS FLASHERS GATES BURNER
OFF
ENGINE
25 25
27 27 CIRCUIT BREAKERS PUSH ON - PULL OFF OFF
28 28
29 29
30 30 H
ON
G
33 33 J
F A B
34 34 E C
35 35 D
36 36
37 37
42 42
45 45
46 46
FRONT
46 46
46 46
46 46
47 47
48 48
49 49
50 50
51 51
VIEW A-A
52 52
100 K3 53
54
53
54
E
61 61
62 62
19 63 63
LEFT
64 64
100 65
66
65
66
70 70
18 71 71
73 73
109 K5 74
77
74
77
78 78
110 79 79
80 80
109A 81 81
RIGHT
83 83
87 87
3 88
90
88
90
113 K6 91
93
91
93 TO BATTERY
POSITIVE
109A
97 97
113A
114
117A
245
98 98
100
115
45
46
K3
20
101 101
REAR
1
K5 106 106
#1 TO
103 K15 107 107
STARTER
51
108
109
108
109
4
100 K6 10 7.5
52
83
110
110
110
110
FEED INTERFACE 81
101 3 10 7.5
MODULE 80
3
113
114
113
114
47 117 117
3 K15 10 5
90
91
117A
155
117A
155
93
104 K16 157 157
SCREED
54
7.5 5 53 165 165
167 167
100
VIEW B-B
173 173
K16 174 174
183 183
102 3 184 184
3 281 281
K17
2 4 282 282
291 291
105 3 292 292
294 294
3 SPARE 15 17
295
296
295
296
297 297
108 K18 331 331
332 332
100
E
245 245
115 115
106 3
3
100 1
BATTERY
STARTER
B B
A A
C D
VIEW E-E VIEW C-C VIEW D-D
4494-105-21 Page 4 of 4 4/03
452/552 Paver
Electrical Schematic
9704-417-36, 9704-417-55, 9704-417-54
12 V.D.C.
STARTER
1 1 3
RANGE
K2 TRAVEL 42 42 3
100 100 2 RANGE SOL.
3 46
PAVE
SUSMIC 10
ENGINE J MANEUVER TRAVEL
ENGINE E-STOP STOP BRAKE CONTROLLER
1 20 21 17 ENG 14 F H F 15 3
RUN K2
15A. 13
MAIN N N
START REL STARTER
KEYSWITCH
A H H RELAY
R R DE-TRACK
17 3
K1 22 3C
R
STOP POWER RELAY
17 RUN 22
RH TRACK LH TRACK
ALTERNATOR
SWITCH SWITCH
START
(1) (2) (7) (8)
R 11
S HOUR/TACHOMETER
22 3 3B 3
B I G
1 (4) (3) (6) (5)
H/T
23 PIN
5A
3A OVERRIDE
A
3
KEY SWITCH B
C
7.5A
D
3
7.5A E
3
F 3A
7.5A
G
3
ECM H 42 3 3
P1-28 P1-2
3
J 3 3
1 2 P1-3
K HYD DUMP
22 351 F H
10A P1-1 P1-9
L COOLING
FUEL PUMP FAN 22 N
M P1-10 352
P1-27
3 H
N 22 R
1 2 P1-12
O
3
RANGE
P CW 331 TRAVEL
10A A P1-23 J
RED
Q STEERING 332 353
B P1-8 PAVE
FUEL PUMP 3 WHEEL P1-18 3
W BRN
SENSOR 333 MANEUVER
1KQ C P1-22
BLK
RUN
WT WATER TEMP. CW
22 3 341 355 3
7 A P1-24 P1-15
I S RED CAL
G PAVER 342
SPEED B P1-19
BRN
1KQ 343 73 3
OP OIL PRESS. C P1-13 P1-7 F
22 8 3 BLK
I S
G 361 74 3
A P1-17 P1-20 R
RED
OIL TEMP. GPI 362
OT CONNECTOR B P1-16
22 9 3 BRN
I S
363 77 3
G C P1-26 P1-6 F
BLK
34 78 3
P1-25 P1-21 R
FUEL LEVEL A 10L
QSB STOP FUEL
22 10
5 I S B
B1 R G RH BRAKE
10R TANK 3 ENG.
C 46 34 34 3 BRAKE
WARNING 25 REL. RELEASE SOL.
D A
6 24
A H F 47
B3 E
34
F N
49 49 3
MAINTENANCE 22 BACKUP ALARM
R (OPTIONAL)
30
B4 A VIBRATORS
VM VOLTMETER OFF
22 3 47 47 47 50 3
I G VIBRATOR SOL.
WAIT TO START ON
28
LIGHTS
OFF LIGHTS RELAY
B11 A 109
22 3
K5 OPTIONAL
ON
TRUCK ENGAGE 61 3
'ENGAGE' SOL.
WATER IN FUEL FLASHER HITCH
FLASHER RELAY 46
OFF
29 22 113 3
A K6 RELEASE 62 3
B2 'RELEASE' SOL.
ON
DIAGNOSTIC
OFF SCREED RAISE 63 3
37 'RAISE' SOL.
B37 LIFT
ON 46
35 LOWER 64 3
'LOWER' SOL.
B35 INCREMENT
FAULT ASSIST
OFF
CODE 36
B36 64 33 3
DECREMENT SCREED ASSIST SOL.(OPT)
ON
LIFT RAISE
THROTTLE
48 47 ALARM
FULL OFF CRFA
2200 RPM B28
3 89C 89B 89A 3 NO MATERIAL
IDLE
LOWER ON FLOW
AUDIBLE ALARM
GENERATOR
OFF HOPPER RAISE 65 3
21B 'RAISE' SOL.
1400 RPM B47 WINGS
ON 46
LOWER 66 3
45 21A 'LOWER' SOL.
OPTION
WIF SENSOR
B40 REAR RAISE 70 3
(LOCATED IN 'RAISE' SOL.
46 FRAME
FUEL FILTER)
GRID HTR RELAYS LOWER 71 3
'LOWER' SOL.
B41 BATTERY + 1
6 AWG
125A FUSE + - LH RAISE 103 3
TWIN K15
GRID 46 GATE
BATTERY + 1 HEATER
B31 LOWER 104 3
UNIT K16
6 AWG
125A FUSE + -
RH RAISE 107 3
K17
46 GATE
NOTE:
ENGINE BLOCK
GROUND 108
LOWER 3
K18
DIAGNOSTIC
TWISTED
J1587 PUBLIC DATA LINK(+)
B49 F
J1587 PUBLIC DATA LINK(-)
B50 G LIGHTS
K5
23030 (7/03)
B
25A. HEAD
A LGTS. WORK
W W W W
LGTS.
J1939 +
C 3
1 J1939 J1939 -
TO D
K1 FLASHERS STROBE
ENGINE
B- 7
J1939 SH K6
4
E 4 113A 114 114 3
A
15A.
VENT
HYD VENT VALVE
5A 3
4 4A
Page 1 of 4
462/562 Paver
1 2
SEE SHEET 2 OF 2 FOR ADDITIONAL CONTROLS
Electrical Schematic
CONSOLE
4 46
3
9704-417-39, 9704-417-56, 9704-417-54
15A.
46 47
100 4 3
4/03
B- 8
100 4 3 46 47 3
GENERATION III
GATES HORN LH CONVEYOR CONTROL
K3
4 100 19 19 3 FEEDER
A A A +14V CONTROL +14V A
30A. SONIC
HORN SW. B B B GND GND B
100 18 18 3
K3
C C C +8V GND C
HORN RELAY D D SIG. SIG. D
K16 E E GND +8V E
100 102
L.H. GATE
MOTOR WAND A B D C A
K15 K16 5 PIN
100 101 YEL RED 102 3 1KQ B
1/2W.
C
10 PIN
101 3 D C A D E
K15 E
5 PIN
46 46 3 3
K18
100 106 81 80
R.H. GATE
MOTOR REMOTE
(A) (B) 98 3 51
98 12
R LH
52 C
(C) 11 87 3 FEED
83 83 EDC
OPENS WITH A B
3 10
MATERIAL 81 81
PRESENT 9 STOP
FEED 80 80
INTERFACE 8
MODULE 3 3
7
47
6
90
5 RH
91 D
4 97 3 FEED
93 93 EDC
3 A B
54
2 STOP
53
1
SCREED 47
4 45
15A. REMOTE
LH AUTOMATIC SCREED CONTROL FEED
NOTE: OVERRIDE 54
WIRE 45 MAT THICKNESS 45
SAME AS (TOWPOINT)
46 ON 47
AUTO
SCREED STOP
ONLY! SET LH AUTO ISOLATION RELAY D
45 152 8 1 3
MAN LAI
152 RH FEED
OVERRIDE 54
155
INC
46
150 150 OFF
45 157
DEC AUTO
3 3 46
A
45 53
91
B
155A
90
C INC. SOL.
157A 155A 4 3 3
155 46 46 3
D
155A
E DEC. SOL.
157A 157A 157 3 A WAND
F
5 6 5 PIN B 1KQ
G E B D C 1/2W.
C
H
D
I 10 PIN RECEPTACLE FOR AUTO CABLE 10 PIN
B D C A E
J
5 PIN FEEDER
A +14V CONTROL` +14V A A A SONIC
B GND GND B B B
RH AUTOMATIC SCREED CONTROL
C +8V GND C C C
MAT THICKNESS
47 (TOWPOINT) D SIG. SIG. D D
AUTO
E GND +8V E E
SET RH AUTO ISOLATION RELAY
45 162 8 1 3
MAN RAI GENERATION III
162 RH CONVEYOR CONTROL
165
INC
160 160
45 167
DEC
3 3
A
45
B SCREED CONTROLS
165A INC. SOL.
C LH INCREASE 171 3
INC. SOL.
167A 165A 4 3 3 SLOPE
165 45
D
167A DEC. SOL.
DECREASE 172 3
E DEC. SOL.
165A 167A 167 3
F
5 6
G INC. SOL.
RH INCREASE 181 3
H 45 SLOPE
I 10 PIN RECEPTACLE FOR AUTO CABLE DEC. SOL.
DECREASE 182 3
J
IN SOL.
OPTIONAL FOR NON-FUEL OIL HEATING LH IN 173 3
45 EXTEND
NOTE:
OUT 174
STANDARD FUEL OIL BURNER CONTROL
BURNER FUEL PUMP
OFF FUEL PUMP MOTOR
4 115 117 117 3 IN SOL.
RH IN 183 3
50A. ON
45 EXTEND
FAN NO.1 LH MAIN BURNER (NO.1) OUT SOL.
OFF FAN MOTOR NO.1 184 3
OUT
115 116 116 3
ON
RH EXT
IN 183
GLOW PLUG NO.1 (CONSOLE)
GLOW PLUG NO.1 46
115 118 118 3
4494-105-22
OUT 184
RH UP SOL.
FAN NO.3 LH EXT. BURNER (NO.3) UP 185 3
OFF FAN MOTOR NO.3 MATCH
115 136 45 HEIGHT
SEE SHEET 1 OF 2 FOR REMAINDER OF SCHEMATIC
136 3
DOWN SOL.
ON DOWN 186 3
GLOW PLUG NO.3
Page 2 of 4
462/562 Paver
3
Electrical Schematics
ITEM PART NO./ PATTERN NO. DESCRIPTION REQ. ITEM PART NO./ PATTERN NO. DESCRIPTION REQ. ITEM LBS/PIECE PART NO./PATTERN NO. DESCRIPTION REQ.
68 END BARRIER AB #1492-EB3 2 46 07504-066 MACH SCREW- #10-32 X 1/2" 1 1 09704-505-97 CONSOLE- TRACK 1
69 RAIL AB #199-DR1 28" 47 07504-052 MACH SCREW- #8-32 X 1/2"U 4 2 04494-105-12 EMBLEM-TRACK 1
70 TERM. GND AB #1492-WG4 4 48 07383-034 CAPSCREW- 3/8"NC X 1/2" 4 3 09704-376-34 HARNESS-TRACK CONSOLE 1
33 8 PLACES 71 46260-005-32 MARKER AB #1492-SM6-12 .8 49 07383-022 CAPSCREW-5/16"NC X 1" 2 4 46061-525-22 CONTROLLER- TRACK STEERING 1
18 18
7 50 07437-135 MACH SCREW- 1/4"NC X 3/4" 2 5 46061-525-21 SENSOR- STEER 1
18
51 07014-017 WASHER- 5/16" 2 6 04418-857 EMBLEM-CAL/RUN 1
52 07014-003 WASHER- 3/8" LOCK 4 7 09704-416-50 POTMETER- SPEED 1
52 54
51 53
28
22 13 50 63 33 3A
3C 42
59 53 07014-002 WASHER- 5/16" LOCK 2 8 09704-416-48 BRACKET- SWITCH MOUNTING 1
46 46 17 47 47 46 64 3
22
51 53 89C 64 22 54 07012-024 HEX NUT- 5/16"NC 2 9 09704-411-34 CABLE-LH 1
16 47 55 07438-023 WASHER-#10 SHKP LK 4 10 09704-411-35 CABLE-RH 1
183
174
184
173
46
46
37 35 70 351
29
22
3 3 46 14 3A 56 07438-022 WASHER-#8 SHKP LK SINT 4 11 45865-002-41 GAUGE- OIL PRESSURE 1
36 71 16 352
57 07440-23 HEX NUT- #10NF 1 12 45865-003-16 GAUGE- OIL TEMP 1
15 34 49
103 107
30
113 58 07440-008 HEX NUT #8 NC 4 13 45865-003-17 GAUGE- WATER TEMP 1
46 46 22 59
22
C
104 108 C B A 42 59 46275-001-02 WIRE LUG-14/16 EYE 9 14 45915-012-08 GAUGE- FUEL LEVEL 1
B
A
A
60 07383-075 CAPSCREW, 1/2-NC X 2-3/4" 2 15 46225-001-24 METER- VOLTMETER 12VDC 1
65 61 109 42 34 3 3
6
61 07012-027 HEX NUT 1/2"NC 4 16 46225-010-17 METER- TACH/HOUR 1
C B A
46 46 22 353 46 13 46 48 18
22
66 62 3 14
30 17 21 12 15
14
37 24 46200-009-21 SWITCH- TOGGLE 2TL1-7 8
29 36 67
59 16
29
59 25 46200-009-40 SWITCH- TOGGLE 2TL1-5 3
26 46200-009-41 SWITCH- TOGGLE 2TL1-50 1
39
11 27 46200-009-62 SWITCH- TOGGLE 4TL1-10D 1
9 38
52 88
LH - FEED - RH
OVERRIDE
WAIT TO
START
ENGINE
START ON RAISE ENGAGE ON
OVERRIDE DE-TRACKED 42 46955-001-43 DIODE- 600V 6A 4
53 89
ONLY
54 98 - REVERSE DIRECTION
WHEN
3 3
6 8
OFF
SCREED
IS ON
- HOLD OVERRIDE
43 45890-100-06 SEAL NUT- 3/8"NEF X 32 28 1
3 89A AUTO STOP OFF LOWER GROUND OFF
+ 46
44 45890-100-29 NUT- 1/4" SELF RETAINING 2
45 45890-800-31 EDGING - 1/16" -B-2-ALUM 4.7'
26 20 25
89A 25 20 22
66 31
SP3 34
31
32
SP2
45
TYP 4 PLCS
4494-105-22 Page 3 of 4 4/03
8
88 462/562 Paver
89 355
Electrical Schematic
89B
CRFA
98 3
9704-417-39, 9704-417-56, 9704-417-54
3 42 VIEW A-A
C D
ENGINE
MEGA
125A 2 2
3A 3A
3C 3C
HEAT
GRID
5 5
6 6
7 7
8 8
9 9
10 10
11 11
15 15
17 17
MEGA 18 18
125A 19 19
21 21
21A 21A POWER
21B 21B 15 15 15 15 15 15 15 30 50
22 22 ON
24 24 ENGINE SCREED CONSOLE F/G/S SPRAYDOWN LIGHTS FLASHERS GATES BURNER
OFF
ENGINE
25 25
27 27 CIRCUIT BREAKERS PUSH ON - PULL OFF OFF
28 28
29 29
30 30 H
ON
G
33 33 J
F A B
34 34 E C
35 35 D
36 36
37 37
42 42
45 45
46 46
FRONT
46 46
46 46
46 46
47 47
48 48
49 49
50 50
51 51
VIEW A-A
52 52
100 K3 53
54
53
54
E
61 61
62 62
19 63 63
LEFT
64 64
100 65
66
65
66
70 70
18 71 71
73 73
109 K5 74
77
74
77
78 78
110 79 79
80 80
109A 81 81
RIGHT
83 83
87 87
3 88
90
88
90
113 K6 91
93
91
93 TO BATTERY
POSITIVE
109A
97 97
113A
114
117A
245
98 98
100
115
45
46
K3
20
101 101
REAR
1
K5 106 106
#1 TO
103 K15 107 107
STARTER
51
108
109
108
109
4
100 K6 10 7.5
52
83
110
110
110
110
FEED INTERFACE 81
101 3 10 7.5
MODULE 80
3
113
114
113
114
47 117 117
3 K15 10 5
90
91
117A
155
117A
155
93
104 K16 157 157
SCREED
54
7.5 5 53 165 165
167 167
100
VIEW B-B
173 173
K16 174 174
183 183
102 3 184 184
3 281 281
K17
2 4 282 282
291 291
105 3 292 292
294 294
3 SPARE 15 17
295
296
295
296
297 297
108 K18 331 331
332 332
100
E
245 245
115 115
106 3
3
100 1
BATTERY
STARTER
B B
A A
C D
VIEW E-E VIEW C-C VIEW D-D
4494-105-22 Page 4 of 4 4/03
462/562 Paver
Electrical Schematic
9704-417-39, 9704-417-56, 9704-417-54
Hydraulic Schematics
Hydraulic Schematics
The following pages contain The hydraulic
schematics for the various configurations of the
500 Series Pavers
Hydraulic Schematics
F TO COOLER PAGE 2
B FROM RESERVOIR
PAGE 2
LH TRACTION PUMP
LH TRACTION DRIVE
5 m
CID * .86
CID
2530 RPM
b2
25 PSI
BALANCE LINES
(OPTIONAL)
TRACK TENSIONING
TRACK TENSIONING TRACK PAVERS ONLY
TRACK PAVERS ONLY
1800 PSI
PRECHARGE
RANGE SHIFT
D TRACK TENSIONING
TRACK TENSIONING
FROM AUXILIARY PUMP TRACK PAVERS ONLY
TRACK PAVERS ONLY
PAGE 2
C
FROM RH CONVEYOR
CHARGE PUMP
PAGE 2
380 PSI
5m
b2 FRONT WHEEL ASSIST
25 PSI TIRE PAVERS ONLY
(OPTIONAL)
9.4 GPM
*
CHARGE FLOW
.86
CID CID 2530 RPM
47.8 CID
REVERSE
6100 PSI
RH TRACTION DRIVE
RH TRACTION PUMP
TRUCK HOOK
(OPTIONAL) LH PULL POINT RH PULL POINT HOPPER WINGS STEERING
SCREED ASSIST TIRE PAVERS ONLY
(SUPPLIED WITH
STRETCH 20) REPHASE PORT
AT EACH END OF
CYLINDER STROKE
E
B A B A B A B A A
D
STEERING
VALVE
B A B A
900
PSI
I T
FLOW TO SCREED P
VALVES
COOLING FAN
FUME FAN
2800 RPM MAX
3750 2400 ACTUAL
SCREED VIBRATORS
RPM
TO TRACK A
TENSION VALVE 10.7 GPM 23.5 GPM 1
.659
PAGE 1 FLOW TO SCREED CID
D VIBRATORS 2800 PSI 2 1.94
TO FRONT
CID
WHEEL ASSIST 3000 PSI
PAGE 1 1500 PSI 2130
5 PSI MAX
RPM
6 m 1.16 2.55 REPHASE PORT
b8 CID CID CROSS SECTION
FLOW FROM SCREED COOLER
VIBRATORS
3
A
A
PAGE 1
25 PSI 25 PSI
C
LH CONVEYOR RH CONVEYOR
AUXILIARY PUMP
9.3 GPM
9.3 GPM
2530
RPM
2530
2530
RPM 1000 PSI
RPM
1.6 GPM
5075 P.O.R.
3800 PSI
3800 PSI
2500 PSI
400 PSI
B 12VDC
TO LH TRACTION
25 PSI PUMP PAGE 1 A
TO RH TRACTION PUMP
PAGE 1
100 MESH
STRAINERS
5 m
b 2
4495-008 Page 2 of 2 4/03
5 PSI