Control Systems Highway Class Paver/Finishers: Task Page No

Control Systems Highway Class Paver/Finishers
TABLE OF CONTENTS
TASK PAGE NO.
Table of Contents ............................................................................................................B-1

Alphabetical Index ..........................................................................................................B-2
Safety Precautions .........................................................................................................B-3
Control Systems Theory of Operation.............................................................................B-4
Control Systems Maintenance and Service ...................................................................B-6
Control Systems Troubleshooting ...................................................................................B-7
Steering Console Assembly (Wheeled) (also see Electrical) .......................................B-15
Operator’s Control Console (Tracked) (also see Electrical)..........................................B-18
Traction Control Console (Wheeled) .............................................................................B-20
Traction Control Console (Tracked)...............................................................................B-25
Pivot Steer Switches (Wheeled) ...................................................................................B-30
Electrical Junction Box (see Electrical section)
Optional Fumes Recovery System (see Hydraulics section)
Automatic Grade & Slope Controls (AGS 6.5 Blaw-Kontrol II) .....................................B-32
Appendix B-1 – Vendor Component Publications Listing ..........................................B-1-1
B-1
Highway Class Paver/Finishers Control Systems
ALPHABETICAL INDEX
TASK PAGE NO.
Appendix B-1 – Vendor Component Publications Listing ..........................................B-1-1

Automatic Grade & Slope Controls (AGS 6.5 Blaw-Kontrol II) .....................................B-32
Blaw-Kontrol II (Automatic Grade & Slope Controls) ....................................................B-32
Control Systems Maintenance and Service ...................................................................B-6
Control Systems Theory of Operation.............................................................................B-4
Control Systems Troubleshooting ...................................................................................B-7
Electrical Junction Box (see Electrical section)
Fumes Recovery System (see Hydraulics section)
Operator’s Control Console (Tracked) (also see Electrical)..........................................B-18
Pivot Steer Switches (Wheeled) ...................................................................................B-30
Safety Precautions .........................................................................................................B-3
Steering Console Assembly (Wheeled) (also see Electrical) .......................................B-15
Table of Contents ............................................................................................................B-1
Traction Control Console (Tracked)...............................................................................B-25
Traction Control Console (Wheeled) .............................................................................B-20
B-2
CONTROL SYSTEMS SAFETY DANGER

Never attempt to pass under low overhead
PRECAUTIONS obstructions, such as bridges or utility wires,
without first confirming there is adequate
clearance. Serious injury or death could
Read and understand the precautions listed in this result. Always lower or remove the exhaust
section before servicing paver. Do no attempt to stack if there is any question about clearance.
perform any servicing you do not understand or feel
you cannot perform safely. CAUTION
Always operate the SmokEater® Ventilation
WARNING Control System when placing paving
Only make adjustments to the Automatic materials which produce fumes.
Level Control or Blaw-Kontrol II with the travel
control lever on the operator’s console set in CAUTION
neutral and the brake switch ON when engine Do not restrict the intake or discharge
is running. This will prevent the machine from openings for any reason. The system will not
moving while allowing joint matcher or perform as intended and may allow increased
Blaw-Kontrol II to function. levels of fumes to reach personnel at operat-
ing stations.
WARNING
Do not attempt to alter or enhance the design CAUTION
of the SmokEater® Ventilation Control Do not operate the SmokEater® Ventilation
System in any way to improve air/fumes flow. Control System without first installing the
The system may not perform as intended and exhaust stack. The system will not perform as
will deliver increased levels of fumes to intended and will deliver increased levels of
personnel at operating stations. fumes to personnel at operating stations.
WARNING CAUTION
Do not put hands, tools or foreign materials When pivot steering, always allow approxi-
into the intake or discharge openings while mately one second before moving Direction-
the system is operating. Serious injury could Speed lever out of neutral to avoid increased
result. wear to the brakes.
WARNING
If foreign material has entered the
SmokEater® Ventilation Control System, do
not attempt to remove the foreign material or
disassemble components until the system
has been turned OFF and the engine shut
down. Serious injury could result.
B-3
CONTROL SYSTEMS THEORY The PF-5500 and PF-5510 tilting control consoles are
located in front of the operator’s seats. The control
OF OPERATION console contains all of the following controls under
lockable cover; main power/engine kill switch, starter
The highway class paver/finisher employs a variety of button, throttle switch, screed switch, parking brake
controls for the operation of the machine. The major switch, parking brake light, vibrator switch, auger
controls are described below. switch, L.H. and R.H. conveyor switches, L.H. and
R.H. flowgate switches, hopper switch, horn button,
The control stations are located on both sides of the engine tachometer/travel speed gauge L.H. console
machine to give the operator a choice of operating only), oil pressure gauge, water temperature gauge,
position based on direction of travel, obstacles in the hydraulic oil temperature gauge, voltage gauge, fuel
area and location of steering reference such as gauge (R.H. console only), and truck hitch switch if
centerline, joint to be matched, curb, etc. machine is equipped with an optional truck hitch.
Below the control console, the control console
pedestal contains the console tilt adjusting knob,
transmission shift knob (PF-5510 only) and the motor
shift knob (PF-5500 only).
2741-10
TYPICAL CONTROL STATION
The traction control consoles are located next to the

operator’s seats. On the PF-3172, PF 3180 and
2965-4
PF-3200 machines they contain the Direction-Speed
levers (forward-stop reverse), and a maximum speed CONTROL CONSOLE – TRACK DRIVEN MACHINE
adjustable stop. The traction control consoles also
employ a Reverse Lockout, a hinged plate which is The PF-3172, PF-3180 and PF-3200 tilting control
used to prevent the Direction-Speed levers from consoles are located in front of the operator’s seats.
going in reverse. The SmokEater® switch is located The control console contains all of the following
on the rear face of the console. On the PF-5500 and controls under lockable cover; main power/engine kill
PF-5510 machines there is no maximum speed switch, starter button, throttle switch, screed switch,
adjustable stop on the traction control consoles. The parking brake switch, parking brake light, vibrator
Direction-Speed levers control steering and travel switch, auger switch, L.H. and R.H. conveyor switch-
speed. The SmokEater® switch is located on the rear es, L.H. and R.H. flowgate switches, hopper switch,
face of the console. horn button, engine tachometer/travel speed gauge
(L.H. console only), oil pressure gauge, water temper-
ature gauge, positract switch, positract light, hydraulic
oil temperature gauge, voltage gauge, fuel gauge
(R.H. console only), truck hitch switch if machine is
equipped with optional front wheel assist. The
steering wheel is located at the bottom, center of the
control console.
Below the control console, the control console

pedestal contains the console tilt adjusting knob and
the transmission shift knob. Pivot steer foot pedals
are located on each side of the bottom of the control
console pedestal.
2965-4
B-4
Optional Blaw-Kontrol II (AGS 6.5) is a very accurate

microprocessor based, control system that automati-
cally maintains the elevation of one side of the screed
with respect to a reference surface (grade) while
maintaining the elevation of the opposite side of the
screed in relation to the first with respect to gravity
(slope). This mode of operation automatically pro-
duces an accurate mat to predetermined or specified
grade and slope from a single reference. The system
can be set up to control the tow point of each side of
the screed with respect to grade by referencing from
both sides of the paver simultaneously.
2741-5
CONTROL CONSOLE – WHEEL DRIVEN MACHINE
Hydrostatic braking holds the machine when in the

NEUTRAL position. If the parking brake switch is on,
spring applied, hydraulically released secondary
braking is also engaged. Secondary braking is internal
to the hydraulic torque hub, and is automatically
engaged if the machine has a total electric power
failure or the main power/engine kill switch is “hit.”
The parking brake will also automatically engage if
there is a sudden drop in General Purpose hydraulic BK-AGS6.5
pressure. These emergency conditions engage the BLAW-KONTROL II (AGS 6.5)
parking brake regardless of switch position.
Optional Automatic Level Control (Joint Matcher) is a
The hydrostatic and parking brakes can be released system that is much less accurate than Blow-Kontrol
manually by using the brake release hand valve and II. This system maintains the elevation of the mat
brake release hand pump. These are used to obtain being placed on one side (single) or both sides (dual)
freewheeling of the machine (for towing purposes of the paver/finisher with respect to a reference
only). These procedures are intended for emergen- surface such as an adjacent mat or curb. It controls
cies only to get the machine off of the job site or onto the screed angle of attack by automatically raising
a trailer for hauling. Under no circumstances should and lowering the tow point of the screed side arm, or
the machine be highway towed with the drive wheels in the case of dual operation, both side arms. The
or track on the ground. Destruction of the hydraulic sensor may be mounted on either side of the machine
torque hubs will result. Refer to Operator’s Manual for (single) depending on the location of the reference
further information and instructions. surface and direction of machine travel.
2728-34
BK-76
BRAKE/SHIFT/TOW VALVE AUTOMATIC LEVEL CONTROL
B-5
CONTROL SYSTEMS • Welds: Look for loose or chipped paint, rust or

gaps where parts are welded together. If you find
MAINTENANCE AND SERVICE a bad weld, report it to your supervisor immediate-
ly.
The control systems govern all paver functions. To • Electrical wires and connectors: Look for cracked
ensure machine availability, preventive maintenance or broken insulation, bare wires and loose or bro-
must be performed before work begins. Preventive ken connectors. Tighten loose connections and
maintenance begins with inspection. make sure wires are in good condition.
Systematic inspection may reveal damage that, if not • Hoses and fluid lines: Look for wear, damage and
corrected, may result in serious damage or failure. leaks. Make sure clamps and fittings are tight. Wet
Any problems revealed during pre-service inspection spots show leaks, of course, but a stain around a
must be reported to the shop foreman or service connector can also mean a leak. If a leak comes
manager. from a loose fitting or connector, tighten it. If
something is broken or worn out, either correct it
The following is a list of inspection criteria which or report it to your supervisor.
should be performed whenever the machine is
serviced. • Brakes: Complete brake (within the torque hub)
system checkout is mandatory before and after
• Keep it clean: Dirt, grease, oil and debris only gets service. Report all brake system discrepancies to
in the way and may cover up a serious problem. your supervisor.
Clean as you work and as needed. Use cleaning
solvent to clean metal surfaces and soap and After inspection, it is important to perform basic
water to clean rubber or plastic material. preventive maintenance as shop policy. Completely
lubricating the machine and checking and refilling
• Bolts, nuts and screws: Check that they are not battery, engine oil, hydraulic and cooling system
loose, missing, bent or broken. Look for chipped levels are recommended as a minimum.
paint, bare metal or rust around bolt heads.
Tighten any that are loose and torque to
specification.
B-6
CONTROL SYSTEMS TROUBLESHOOTING
TROUBLESHOOTING
The troubleshooting guides in this section list the common malfunctions which may be found
during the operation or maintenance of the machine. You should perform the test/inspections
and corrective actions in the sequence listed.
This manual cannot list all malfunctions that may occur, nor all tests or inspection and correc-
tive actions. If a malfunction is not listed or it is not corrected by the listed corrective actions,
notify your supervisor.
Before taking action to correct a possible malfunction, follow these rules:
• Question the operator if possible to obtain any information that might help determine the
cause of the problem.
• Never overlook the chance that a problem could be of simple origin. The problem could be
corrected with minor adjustments.
• Use all senses to observe and locate troubles.
• Use test instruments or gauges to help you determine and isolate problems.
• Always isolate the system where the malfunction occurs and then locate the defective
component.
TROUBLESHOOTING GUIDE
ENGINE CRANKS BUT WILL NOT START
(All main switches ON)
PROBLEM CAUSE(S) REMEDY(S)
No fuel in tank. 1. Operator error. 1. Check fuel level in tank. Fill tank.
No fuel to engine. 2. Various 2. Check voltage at fuel injection pump.

possibilities. Check fuel filter(s). Replace.
Check fuel lines to engine. Clean lines or replace.
Check fuel pump voltage & function. Repair or
replace.
Bleed air from fuel system.
Check injectors & injection fuel lines. Clean or
replace.
Contaminated fuel 3. Bad fuel. 3. Check tank. Drain and refill.

in tank.
Incorrect fuel in 4. Wrong fuel. 4. Check tank. Drain and refill.

tank.
B-7
CONTROL SYSTEMS TROUBLESHOOTING (CONTINUED)
ENGINE CRANKS BUT WILL NOT START (All main switches ON)
Slow cranking 5. Various 5. Cold weather. Disengage clutch.

engine. possibilities. Check battery voltage. Charge or replace.
Check battery electrolyte level. Fill and charge.
Check battery terminals. Clean and tighten.
Check engine ground. Clean. Tighten. Replace.
Check voltage through battery master
disconnect switch. Replace.
Other engine 6. Various 6. *See engine manual.

problems. possibilities.
*See Cummins Engine Operator’s Manual
Note: The above manual covers additional less

likely problems.
B-8
ENGINE WILL NOT CRANK (All main switches ON)
Traction lever(s) not 1. Operator error. 1. Check that both traction control levers are both
in neutral. in neutral position. Reposition levers.
Low or dead 2. Battery 2. Check voltage at battery terminals. Charge or

battery. worn/alternator replace. Check electrolyte level. Fill and charge.
not charging. Test alternator. Repair or replace as needed.
Poor battery 3. Lack of 3. Check terminal connections. Clean and tighten.

connections. maintenance.
Poor battery 4. Lack of 4. Check ground cable. Clean and tighten.

ground. maintenance.
Poor starter motor 5. Lack of 5. Check starter connections. Clean and tighten.
connections. maintenance.
Open electrical 6. Loose 6. Check for wire off any terminal in circuit.
circuit. connection. Reconnect.
Faulty “neutral 7. Misadjusted or 7. Check position, voltage and continuity.

start” limit switches faulty switch. Reposition switch(es) (see number 1). Replace
on traction pumps. switch(es).
One switch on
wheeled machines,
two on tracked.
Faulty starter motor 8. Worn or 8. Check voltage and function. Replace.

solenoid. damaged.
Faulty “start” relay 9. Overheated or 9. Check voltage and continuity. Replace.

(inside electrical shorted.
junction box).
Faulty “power” relay 10. Overheated or 10. Check voltage and continuity. Replace.
junction box).
B-9
ENGINE RUNS PROPERLY BUT WILL NOT MOVE – FORWARD OR REVERSE
Brake switch(es) 1. Operator error. 1. Check operating position. Reposition.

engaged
No hydraulic fluid in 2. Leak or lack of 2. Check hydraulic tank dip stick. Fill.
tank maintenance.
Clutch not engaged 3. Operator error. 3. Check clutch lever. Engage or adjust clutch.
Hydraulic filter(s) 4. Lack of 4. Check filter(s). Replace filter(s).

plugged maintenance.
Open traction (shift) 5. Loose 5. Check for wire off any terminal in circuit.
electrical circuit connection. Reconnect.
Traction pump(s) 6. Various 6. Check linkage. Repair or replace.

not stroking possibilities. Check MDC on pump(s). Repair or replace.
Check charge pressure. Repair or replace.
Faulty “brake” 7. Faulty switch. 7. Check voltage and continuity. Replace.

switch on console
Faulty “brake” relay 8. Overheated or 8. Check voltage and continuity. Replace.

junction box)
Faulty “motion/ 9. Overheated or 9. Reset. Check voltage and continuity. Replace.

brake” circuit shorted.
breaker (inside
electrical junction
box)
Faulty hydraulic 10. Worn or faulty. 10. Repair or replace.

motor
Faulty planetary 11. Worn or faulty. 11. Repair or replace.

torque hub
B-10
MACHINE WILL NOT STEER PROPERLY – TRACK DRIVEN
Equal traction lever 1. Various 1. Check linkage from levers to traction pumps.
movement does not possibilities. Adjust.
produce straight Check both L.H. and R.H. traction pumps for
travel. equal charge pressure. Adjust.
Check either L.H. or R.H. brake (within torque
hub) not released. Repair or replace.
Check operation of positive traction valves.
Replace coil(s). Clean orifice(s). Replace.
Check both L.H. and R.H. traction motor in
same shift position. Replace solenoid.
Check shaft switch position. Reposition.
Replace.
Faulty traction 2. Bad coil/valve 2. Check both L.H. and R.H. traction motor in
motor shift solenoid stuck. same shift position. Replace coil. Replace sole-
noid.
Faulty shift switch 3. Worn or faulty. 3. Check shift switch position. Reposition. Replace.
(on operator’s
console)
Faulty 4. Bad coil/valve 4. Check charge pressure. Check operation of

brake/shift/tow stuck. valves. Replace.
valve
Faulty planetary 5. Worn or 5. Check either L.H. or R.H. brake (within torque
torque hub damaged. hub) not released. Repair or replace.
B-11
MACHINE WILL NOT STEER PROPERLY – WHEELED MACHINE

Pivot steer foot 1. Operator 1. Disengage switch. Repair. Replace.

pedal(s) not error/faulty
engaged. switch.
Faulty pivot steer 2. Bad coil/valve 2. Check voltage. Replace coil. Replace solenoid.
solenoid valve (on stuck.
traction pump(s))
Faulty positive 3. Bad coil/valve 3. Check operation. Replace coil. Clean orifice.
traction valve(s) stuck/orifice Replace.
clogged.
Faulty traction 4. Bad coil/valve 4. Check both L.H. and R.H. traction motor in shift
motor shift solenoid stuck. position. Replace coil. Replace solenoid.
Faulty shift switch 5. Worn or faulty. 5. Check shift switch position. Reposition. Replace.
(on operator’s
console)
Faulty brake/shift/ 6. Bad coil/valve 6. Check charge pressure. Check operation of

tow valve stuck. valves. Replace.
Faulty planetary 7. Worn or 7. Replace either L.H. or R.H. brake (within torque
torque hub damaged. hub) not released. Repair or replace.
Steering linkage not 8. Lack of 8. Check linage (below hopper). Grease.

greased maintenance.
Steering linkage 9. Worn or 9. Check tie rods (below hopper). Straighten rods.
bent or worn damaged. Adjust or replace rod ends.
Faulty steering units 10. Worn seals. 10. Try opposite operator’s console. Repair or replace.
Faulty steering 11. System 11. Check all hoses, tubes and fittings. Repair or
hydraulic circuit leaking. replace.
Faulty steering 12. Worn seals. 12. Check for piston leak-by with cylinder fully
cylinders extended and retracted and alternate hoses dis-
connected. Replace O-ring seals.
Worn king pin 13. Excessive 13. Check for free pivot movement of wheels with
bearings wear. steering cylinders disconnected. Replace bearings.
Worn wheel spindle 14. Excessive 14. Check for free, smooth rotation of wheels.
bearings wear. Replace bearings.
B-12
FWA (FRONT WHEEL ASSIST) WILL NOT OPERATE
FWA switch is ON 1. Wrong shift 1. Check that transmission shift switch is at “1” or
but bogie wheels switch posi- “2” position and traction lever is pushed
do not turn. tion/bad valve. FORWARD. Check manual override on bypass
valve. Check voltage and continuity of bypass
valve coil. Replace coil.
Open electrical 2. Loose wire 2. Check L.H. and R.H. console plug-in(s) at
circuit. connection. electrical junction box. Engage plug-in(s).
Check for loose connection at any terminal in
circuit. Reconnect.
Faulty “motion” limit 3. Switch worn or 3. Check operation, voltage and continuity. Adjust
switch in L.H. misadjusted. switch. Replace switch.
traction console.
Faulty “motion” 4. Relay bad. 4. Check voltage and continuity. Replace relay.
relay inside
electrical junction
box.
Faulty “transmis- 5. Switch worn or 5. Check voltage and continuity. Replace

sion shift” faulty. switch(es).
switch(es) on oper-
ator’s consoles.
6. Switch worn or 6. Check voltage and continuity. Replace
Faulty “FWA” faulty. switch(es).
switch(es) on
operator’s con-
soles. 7. General 7. Check output flow of general purpose pump.
purpose pump Replace pump.
Inadequate general worn
purpose pump flow.
B-13
PARKING BRAKE WILL NOT RELEASE
Brake does not 1. Switch bad / 1. Check voltage and continuity of switch. Replace
release when clutch slipping. switch. Check clutch adjustment. Adjust clutch.
switch is OFF.
Faulty 2. Valve stuck or 2. Check charge pressure. Check operation of

brake/shift/tow contaminated. brake/shift/tow valves. Replace valve(s) or
valve. coil(s).
Faulty “brake” relay 3. Relay bad. 3. Check voltage and continuity. Replace relay.
inside electrical
junction box.
Faulty “motion/ 4. Short in circuit 4. Locate short in circuit. Reset breaker. Check
brake” circuit or circuit voltage and continuity. Replace breaker.
breaker inside breaker bad.
electrical junction
box.
Faulty “console” 5. Short in circuit 5. Locate short in circuit. Reset breaker. Check
circuit breaker or circuit voltage and continuity. Replace breaker.
inside electrical breaker bad.
junction box.
Open electrical 6. Loose wire 6. Check L.H. and R.H. console plug-ins at
circuit. connection. electrical junction box. Engage plug-ins. Check
for wire off of any circuit terminal. Reconnect
wires.
Faulty planetary 7. Low oil level or 7. Check fluid level. Refill. Replace clutch packs
torque hub. faulty brakes within torque hub. Replace torque hub.
within torque
hub.
B-14
STEERING CONSOLE ASSEMBLY (WHEELED)

This procedure covers:
✓ Removal Inspection/Specification ✓ Installation

✓ Disassembly ✓ Assembly Adjustments
Special Cleaning Component Test ✓ Equipment Preparation
Machine Set-up Special Tools Fabricated Tools

• Machine blocked to prevent movement. ✓ Steering wheel puller ✓ None
• Battery disconnected or battery master disconnect
switch turned OFF.
• Catch container for hydraulic fluid (2 pts., 1L).
Note: Refer to the Electrical Section for additional information concerning electrical components within the
console.
B-15
STEERING CONSOLE Step 3:

Disconnect the control box.
ASSEMBLY (WHEELED) a. Remove the control panel plate mounting
screws (7).
REMOVAL
Step 1:
Remove steering wheel.
a. Remove rubber cover at the center of wheel.
b. Remove nut (1) and washer (2).
c. Use wheel puller to remove steering wheel (3)
from steering column (4). 7
2741-10
b. Pull the control panel out enough to flip it over

and rest it against the steering wheel
c. Tag and disconnect wires from switches and
buttons.
707-070A
Step 2:
Remove steering unit assembly.
a. Remove the rear cover of the console.
b. Remove bolts (5) and disconnect console
assembly from the pedestal.
c. Disconnect the hydraulic hoses (6) at the base
of the steering unit.
d. Mark, cap and plug all hoses and steering
ports.
2724-11
5
6
2741-10
B-16
DISASSEMBLY ASSEMBLY
Step 1: Step 1:
Remove operator’s control console. OPTIONAL: If further disassembly of the steering
a. Disconnect wire harness (1) from main unit was required, refer to vendor material for
electrical junction box. assembly.
Step 2:
Install electrical switches, wiring, control console
and/or steering unit by reversing the disassembly
procedures.
1 INSTALLATION
Install the steering console assembly be reversing the
disassembly procedures.
NOTE
Steering column is keyed. Ensure steering
wheel is positioned properly before installing.
2965-14
EQUIPMENT PREPARATION
b. Disconnect steering hydraulic hoses (2). Step 1:
Connect battery or turn battery master disconnect
switch ON.
Step 2:
Check hydraulic tank fluid level. Fill if necessary.
Step 3:
Test steering console.
a. Move blocks away from tires.
b. Start engine.
c. Move machine forward. Turn wheels to the left
and to the right to make sure machine is
steering properly.
2741-5
c. Mark, cap and plug hoses and fittings.

d. Disconnect wiring to transmission shift switch.
e. Remove control console pedestal mounting
bolts.
f. Lift console off machine.
Step 2:
OPTIONAL: If further disassembly of the steering
unit is required, refer to Appendix B-1 for a list of
available vendor publications.
B-17
OPERATOR’S CONTROL CONSOLE (TRACKED)


✓ Disassembly ✓ Assembly ✓ Adjustments

• Machine blocked to prevent movement. ✓ None ✓ None
switch turned OFF.
console.
B-18
OPERATOR’S CONTROL
CONSOLE (TRACKED)
REMOVAL
Step 1: 3
Disconnect the control box.
a. Remove the control panel mounting screws
(1).
b. Pull the control panel out enough to flip over.
c. Tag and disconnect wires from switches and
buttons.
2724-14
1
ASSEMBLY
Install the electrical switches, wiring and control
console by reversing the disassembly procedures.
INSTALLATION
Install the operator’s console assembly by reversing
the removal procedures.
EQUIPMENT PREPARATION
2965-2
Step 1:
DISASSEMBLY Connect battery or turn battery master disconnect
switch ON.
Step 1:
Remove operator’s control console. Step 2:
a. Disconnect wire harness (2) from main Check operation of control console switches and
electrical junction box. buttons.
2965-14
b. Disconnect wiring to transmission shift switch.

c. Remove control console pedestal mounting
bolts (3).
d. Lift console off machine.
B-19
TRACTION CONTROL CONSOLE (WHEELED)



switch turned OFF.
B-20
TRACTION CONTROL Step 2:

Remove reverse lockout/gate plate (3).
CONSOLE (WHEELED) a. Lift flap up.
b. Remove gate plate mounting screws.
REMOVAL
NOTE
PF-3200s prior to S/N 320002-01 and
PF-3180s prior to S/N 318002-01 use a solid
rod to connect to the cross-shaft instead of a
cable arrangement.
3
Step 1:
Disconnect traction rod (1) or cable (2) control
linkage.
2724-20
Step 3:
Remove control lever assembly (4) from console.
a. Disconnect electrical wire harnesses (5) to
limit switch and Fumes Recovery switch.
1 b. Remove control lever mounting bolts.
c. Lift reverse lockout gate and control lever
assembly out of console.
whcnsl.2
Rod version used on PF-3200s before S/N 320002-01

and PF-3180s before S/N 318002-01.
4
5
2
whcnsl.1
trcnsl.1
Cable version used on PF-3200s beg. S/N 320002-01

and PF-3180s beg. S/N 318002-01 and all PF-3172s.
B-21
DISASSEMBLY (CABLE DISASSEMBLY

VERSION) Step 1:
Remove lever tension assembly (1).
Step 1: a. Remove mounting bolts.
Remove pivot pin (1), spring washers (2) and b. Remove assembly.
friction pad (3) as needed.
3
1
1
0960-088
Step 2:
Remove limit switch and actuator (2). (L.H.
console only.)
a. Remove wire assembly (3) to limit switch.
b. Remove switch bracket mounting bolts.
c. Remove switch from assembly.
wlhndl.1 3 2
Step 2:
Remove limit switch (4) and actuator (5). (L.H.
console only.)
a. Remove mounting bolts (6) from limit switch
mounting bracket (7).
b. Remove actuator mounting nut (8).
c. Remove limit switch (4).
6 5 7
6 0960-089
8
4
trcnsl.3
B-22
Step 3: Step 5:
Lift rear center deck. Remove the traction control cable (8).
a. Loosen the lock nut (9) at rod ends.
Step 4:
Remove the long shaft (4).
a. Remove coupling (5), key and set screw (both
sides).
b. Remove flange bearings (6), if desired.
8
9
1144-013
b. Remove clamps.
c. Remove traction control cable from traction
control pumps (10).
6
whcnsl.2 10
Step 4:
Remove the short shaft (7) (both sides).
a. Remove the flange bearing (both sides).
b. Pull shaft through the lower cam.
5510pmp.1
ASSEMBLY/INSTALLATION
17 Install traction control (wheeled machines) by reversing
disassembly and removal procedures.
7
19 IMPORTANT
The force to move traction levers should be
adjusted to 1 lb. +/- 1/2 lb.
18 BK-73A
B-23
ADJUSTMENT EQUIPMENT PREPARATION

Step 1: Step 1:
Connect battery or turn battery master disconnect Make sure control levers are in the neutral
switch ON. position. Start engine.
Step 2: Step 2:
Adjust limit switch (L.H. console only). Test traction control.
IMPORTANT IMPORTANT
In order to start machine, limit switch must be Traction levers should remain in any position
fully extended in notch on cam. they are placed, but move easily when
repositioned.
a. Remove L.H. console reverse-lockout/gate
plate (1). a. Move levers forward and reverse to check
b. Adjust switch actuator shaft length so that the machine movement and neutral position.
roller just touches cam inside notch when b. Adjust friction unit as required.
lever is in neutral position.
c. Verify switch operation: With lever out of NOTE
neutral, engine should start. There is no neutral adjustment on the traction
d. Install L.H. console reverse lockout/gate plate. drive pumps. Neutral adjustment is made by
adjusting the rod ends of the traction control
cables.
2724-20
B-24
TRACTION CONTROL CONSOLE (TRACKED)



switch turned OFF.
console.
B-25
TRACTION CONTROL Step 3:

Disconnect the limit switch (5). (L.H. console
CONSOLE ASSEMBLY only).
a. Remove the wire clamps.
(TRACKED) b. Tag and disconnect wires to the limit switch.
c. Remove limit switch, if necessary.
REMOVAL
Step 1:
Remove the console side cover plate.
a. Remove six mounting bolts on the interior side
of the console.
b. Remove four allen bolts at the top corners of
the black folding plate (1) and lay the folding
plate over.
c. Access the brass pivot bolt (2) to loosen or
tighten friction in the handles, if necessary.
5
1
2
trcnsl.1
Step 4:
Disconnect the Fumes Recovery switch (6).
a. Remove the wire clamps.
b. Tag and disconnect wires to switch.
c. Remove switch, if necessary.
2965-4
Step 2:
Remove the nut (3) and disconnect rods from the 6
L.H. and R.H. cross shaft cables (4).
trcnsl.1
4
Step 5:
Remove the traction control console assembly.
a. Remove traction control console mounting
bolts.
b. Lift console off machine.
2965-4
B-26
DISASSEMBLY Step 3:
Disconnect L.H. and R.H. control cables (5). (L.H.
Step 1: side of machine only.)
Remove rods from cams inside control console. a. Disconnect cable from cross-shafts.
a. Remove nut (1) securing rod to the cams.
b. Remove rods from the control console.
NOTE 5
Do not change length of the rods if machine
has been tracking properly. See “Adjustment”
section if necessary.
2965-5
b. Disconnect cables from the traction pumps (6).
6
2965-4
Step 2:
Remove control arms.
a. Remove handle screws (2).
b. Remove screws on top panel (3). It is neces-
sary for cover plate to move freely.
c. Push one control arm handle down at a time.
5510p2.tif
d. Remove control arms (4).
e. Remove bearings if desired.
ASSEMBLY/INSTALLATION
2 Install the traction control console (tracked machines)
by reversing the disassembly and removal
procedures.
3
2965-4
B-27
ADJUSTMENT a. Position both L.H. and R.H. travel control

levers back against the reverse-lockouts. With
IMPORTANT the engine running, no machine movement
In order to start machine, limit switch must be should occur in this position.
fully extended in notch on cam. b. Adjust control rods (2) inside each console if
travel levers are not against reverse-lockouts.
Step 1: Measure the length of the control rods. The
Adjust limit switches (1). (L.H. console only.) rods should measure 10" as illustrated.
Remove, adjust and install the rods to get
IMPORTANT equal contact of the travel control levers on
If the engine does not start when both travel the reverse lockouts.
control levers are positioned in neutral, but
starts after some movement of the levers, the
neutral start/forward motion limit switches
need adjustment. 2
a. Remove L.H. console side plates.
b. Adjust switch shaft length so that the roller just
touches cam inside notch when levers are in
neutral position. Tighten lock nuts.
10"
5510trcns.3
c. Attach cable ends to the pump levers.

d. Push traction levers forward so they hit the
end of slots and adjust cables so they are
trcnsl3.tif approximately 1/8" from full stroke of the pump
c. Connect battery or turn battery master arm.
disconnect switch ON.
d. Verify switch operation: With lever out of
neutral, engine should not start. A clicking
noise should be heard as the rollers enter and
leave the cam openings.
e. Test IN MOTION ONLY function by turning
vibrators on while travel levers are in neutral.
Then push levers forward. Vibrators should
activate immediately.
f. Install L.H. console side plates if work is
complete.
Step 2:
16º
Adjustment of direction-speed (travel) controls.
WARNING
Do not run engine while travel control linkage
is disconnected. Machine could move, caus-
ing property damage, personal injury or
death. 5510pmpcnt.tif
B-28
e. Tighten jam nuts. EQUIPMENT PREPARATION

f. Test drive machine in a flat open area.
g. If machine steers left (right track faster), Step 1:
lengthen L.H. cable or shorten R.H. cable in Test traction control.
1/2-turn increments at the forward cable end. a. Make sure control levers are in the neutral
If machine steers right (left track faster), position. Start engine.
lengthen R.H. cable or shorten L.H. cable in b. Move levers forward and reverse, together
1/2-turn increments at the forward pump end. and separately, to check machine tracking,
steering and neutral position.
5510p2.tif
B-29
PIVOT STEER SWITCHES (WHEELED MACHINES)


Disassembly Assembly Adjustments

switch turned OFF.
B-30
PIVOT STEER SWITCHES INSTALLATION

Install the pivot steer switches by reversing the
NOTE removal procedures.
This procedure is for the PF-3200, PF-3180
and PF-3172 models only (wheeled
machines). EQUIPMENT PREPARATION
Step 1:
REMOVAL Connect battery or turn battery master disconnect
switch ON.
Step 1:
Remove cover from steering console. Step 2:
Check hydraulic tank fluid level. Fill if necessary.
Step 2:
Remove pivot steer switch assembly (1). Step 3:
a. Disconnect electrical (2) to pivot steer switch. Test pivot steer switches
b. Remove cap screws (3) from below foot pedal a. Move blocks away from tires.
platform. b. Start engine.
c. Remove foot pedal. c. Move machine forward. Apply pressure to both
right and left pivot steer switches to engage
brake to back wheels and move machine to
the opposite direction than the pivot steer
switch that’s engaged.
2724-14
2724-22
B-31
AUTOMATIC GRADE & SLOPE CONTROLS (AGS 6.5 BLAW-KONTROL II)


Disassembly Assembly Adjustments

switch turned OFF.
B-32
AUTOMATIC GRADE & SLOPE

CONTROLS
4
REMOVAL
Step 1:
Remove grade sensor assembly (1).
a. Unplug grade sensor cable(s) assembly from
grade/slope controller (2).
2 2966-5
Step 3:
Remove Blaw-Kontrol valve(s) if necessary. See
“Valves” on pages D-39 to D-46 of the Hydraulics
module for testing and repair procedures.
1
NOTE
Valves may be tested or repaired in position.
NOTE
Before performing any work on any valve it is
blawkntrl.2
important to clean the exterior of the affected
b. Remove grade sensor (3). valve manifolds of any dirt, etc. to prevent
contamination from entering the hydraulic
system.
a. If necessary, disconnect hydraulic hoses (5) to

the valve manifold (6). Mark, cap and plug
hoses and fittings.
3 b. Turn the motion control valve (7) counterclock-
wise to remove it from the manifold. Be careful
not to allow contamination to enter the valve
cavity.
c. Disconnect wire (8) from the solenoid valve
coils (9).
d. Remove the coil nuts and slide coil off
cartridge (10).
10
8
blawkntrl.1 9
Step 2:
Remove side arm cylinder (4).
a. Disconnect hydraulic hoses.
b. Mark, cap and plug hoses and fittings.
c. Remove cotter pins. 5
d. Drive clevis pin out of clevis and base.
NOTE 7
Control valves are located below deck, 6
behind the side arm cylinders on the
transverse bulkhead, L.H. and R.H. sides.
0718-75
B-33
e. Loosen mounting nut on valve cartridge and c. Replace potentiometer (12) if needed.
rotate the solenoid valve counterclockwise to
remove it from the manifold. Be careful not to
allow contamination to enter the valve cavity.
DISASSEMBLY
Step 1:
Disassemble the grade sensor mounting
assembly.
a. Remove shoe (1) from wand (2).
b. Remove wand from grade sensor (3).
c. Remove grade sensor from mounting tube (4).
d. Remove mounting tube from pivot(5).
e. Remove pivot from bracket (6). 12
f. Remove bracket from extension tube (7).
g. Remove extension tube from exterior tube
grsnsr.3
bracket support.
h. Remove interior tube support bracket (8) from Step 3:
edger guide mount tube (9). Disassemble the power switch.
a. Remove the rear cover (13).
b. Remove the power switch (14).
5 6
4
7
13
8
2 14
9
1 3
blawkntrl.3
Step 2:
swtbx.2
Disassemble the grade sensor assembly.
a. Remove the front plate mounting screws (10). c. Replace the power switch (15) if needed.
b. Remove potentiometer mounting screws (11). d. Replace the circuit breakers (16) if needed.
11
10
10
16
11
15
grsnsr.1 swtbx.3
B-34
Step 4: ASSEMBLY/INSTALLATION
Disassemble the slope sensor assembly.
a. Remove front plate mounting screws (17). Install the Blaw-Kontrol II components by reversing
the disassembly and removal procedures.
ADJUSTMENT
Step 1:
Refer to Blaw-Kontrol II AGS 6.5 Operator's
17 Manual for adjustment procedures.
Step 2:
See “Electrical” section for troubleshooting
procedures and use of the “CH” mode.
spsnsr.1
b. Replace inclinometer (18) if needed.

c. Replace filter (19) if needed.
d. Replace receptacle (20) if needed.
20 19 18
spsnsr.3
B-35
APPENDIX D-1
VENDOR COMPONENT PUBLICATIONS LISTING
The following component publications are available from Blaw-Knox Technical Publications Department free of
charge to authorized Blaw-Knox dealers.
To order, please provide the following information:

• Dealer Name
• Name of Service Manager
• Dealer Address
• Dealer Phone and Fax Numbers
• Machine Model and Serial Numbers
Send your request to:

Blaw-Knox Construction Equipment Corp.
750 Broadway Avenue East
Mattoon, Illinois 61938-4600
COMPONENT BLAW-KNOX VENDOR PUBLICATION TITLE

PART NO.
Char-Lynn steering unit 002-2-086-00 Eaton Char-Lynn power steering repair information (7-304)
B-1-1

Control Systems Highway Class Paver/Finishers: Task Page No

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Control Systems Highway Class Paver/Finishers: Task Page No

Hochgeladen von

Copyright:

Verfügbare Formate

Control Systems Highway Class Paver/Finishers

Table of Contents ............................................................................................................B-1

Appendix B-1 – Vendor Component Publications Listing ..........................................B-1-1

CONTROL SYSTEMS SAFETY DANGER

The traction control consoles are located next to the

Below the control console, the control console

Optional Blaw-Kontrol II (AGS 6.5) is a very accurate

CONTROL CONSOLE – WHEEL DRIVEN MACHINE

Hydrostatic braking holds the machine when in the

CONTROL SYSTEMS • Welds: Look for loose or chipped paint, rust or

CONTROL SYSTEMS TROUBLESHOOTING

Before taking action to correct a possible malfunction, follow these rules:

• Use all senses to observe and locate troubles.

PROBLEM CAUSE(S) REMEDY(S)

No fuel to engine. 2. Various 2. Check voltage at fuel injection pump.

Contaminated fuel 3. Bad fuel. 3. Check tank. Drain and refill.

Incorrect fuel in 4. Wrong fuel. 4. Check tank. Drain and refill.

CONTROL SYSTEMS TROUBLESHOOTING (CONTINUED)

PROBLEM CAUSE(S) REMEDY(S)

Slow cranking 5. Various 5. Cold weather. Disengage clutch.

Other engine 6. Various 6. *See engine manual.

*See Cummins Engine Operator’s Manual

Note: The above manual covers additional less

CONTROL SYSTEMS TROUBLESHOOTING (CONTINUED)

ENGINE WILL NOT CRANK (All main switches ON)

PROBLEM CAUSE(S) REMEDY(S)

Low or dead 2. Battery 2. Check voltage at battery terminals. Charge or

Poor battery 3. Lack of 3. Check terminal connections. Clean and tighten.

Poor battery 4. Lack of 4. Check ground cable. Clean and tighten.

Faulty “neutral 7. Misadjusted or 7. Check position, voltage and continuity.

Faulty starter motor 8. Worn or 8. Check voltage and function. Replace.

Faulty “start” relay 9. Overheated or 9. Check voltage and continuity. Replace.

CONTROL SYSTEMS TROUBLESHOOTING (CONTINUED)

ENGINE RUNS PROPERLY BUT WILL NOT MOVE – FORWARD OR REVERSE

PROBLEM CAUSE(S) REMEDY(S)

Brake switch(es) 1. Operator error. 1. Check operating position. Reposition.

Hydraulic filter(s) 4. Lack of 4. Check filter(s). Replace filter(s).

Traction pump(s) 6. Various 6. Check linkage. Repair or replace.

Faulty “brake” 7. Faulty switch. 7. Check voltage and continuity. Replace.

Faulty “brake” relay 8. Overheated or 8. Check voltage and continuity. Replace.

Faulty “motion/ 9. Overheated or 9. Reset. Check voltage and continuity. Replace.

Faulty hydraulic 10. Worn or faulty. 10. Repair or replace.

Faulty planetary 11. Worn or faulty. 11. Repair or replace.

CONTROL SYSTEMS TROUBLESHOOTING (CONTINUED)

MACHINE WILL NOT STEER PROPERLY – TRACK DRIVEN

PROBLEM CAUSE(S) REMEDY(S)

Faulty 4. Bad coil/valve 4. Check charge pressure. Check operation of

CONTROL SYSTEMS TROUBLESHOOTING (CONTINUED)

MACHINE WILL NOT STEER PROPERLY – WHEELED MACHINE

Pivot steer foot 1. Operator 1. Disengage switch. Repair. Replace.

Faulty brake/shift/ 6. Bad coil/valve 6. Check charge pressure. Check operation of

Steering linkage not 8. Lack of 8. Check linage (below hopper). Grease.

CONTROL SYSTEMS TROUBLESHOOTING (CONTINUED)

FWA (FRONT WHEEL ASSIST) WILL NOT OPERATE

PROBLEM CAUSE(S) REMEDY(S)

Faulty “transmis- 5. Switch worn or 5. Check voltage and continuity. Replace

CONTROL SYSTEMS TROUBLESHOOTING (CONTINUED)

PARKING BRAKE WILL NOT RELEASE

PROBLEM CAUSE(S) REMEDY(S)

Faulty 2. Valve stuck or 2. Check charge pressure. Check operation of

STEERING CONSOLE ASSEMBLY (WHEELED)

✓ Removal Inspection/Specification ✓ Installation

Machine Set-up Special Tools Fabricated Tools