Material Handling System Highway Class Paver/Finishers: Task Page No

Material Handling System Highway Class Paver/Finishers
TABLE OF CONTENTS
TASK PAGE NO.
Table of Contents ............................................................................................................C-1

Alphabetical Index ..........................................................................................................C-2
Safety Precautions .........................................................................................................C-3
Material Handling System Theory of Operation .............................................................C-4
Material Handling System Maintenance and Service .....................................................C-6
Material Handling System Troubleshooting ....................................................................C-7
Hopper Sides/Wings (Hinge Rebuild) ...........................................................................C-13
Hopper Overflow Guards ..............................................................................................C-15
Power Flow Gates.........................................................................................................C-17
Oscillating Push Roller Assembly .................................................................................C-21
Optional Truck Hitch Assembly .....................................................................................C-23
Truck Hitch Cylinder (see Hydraulics)
Conveyor Chain and Bar ..............................................................................................C-28
Conveyor Floor Plates ..................................................................................................C-34
Auger/Conveyor Drive Assembly (Feeder Drive)..........................................................C-37
Auger/Conveyor Motor/Planetary Drive .................................................................C-44
Auger/Conveyor Drive Chain and Sprockets .........................................................C-48
Conveyor Drive Shaft and Sprockets .....................................................................C-53
Augers, Shafts and Bearings..................................................................................C-58
Auger and Tunnel Guard Extensions............................................................................C-61
Power Flight Augers
Optional Power Flight Augers ................................................................................C-63
Cylinder (see Hydraulics)
Side Arms (see Screed)
Optional Mixer/Agitator..................................................................................................C-68
Pump (see Hydraulics)
Motor (see Hydraulics)
Optional Material Level Indicator ..................................................................................C-71
Appendix C-1 Vendor Component Publications Listing ...............................................C-1-1
C-1
Highway Class Paver/Finishers Material Handling System
ALPHABETICAL INDEX
TASK PAGE NO.
Appendix C-1 Vendor Component Publications Listing ...............................................C-1-1

Arms, Side (see Screed)
Augers, Optional Power Flight ......................................................................................C-63
Auger Cylinder, Power Flight (see Hydraulics)
Augers, Shafts and Bearings ........................................................................................C-58
Auger and Tunnel Guard Extensions............................................................................C-61
Auger/Conveyor Drive Assembly (Feeder Drive)..........................................................C-37
Auger/Conveyor Motor/Planetary Drive ........................................................................C-44
Bearings, Augers and Shafts ........................................................................................C-58
Chain and Sprockets, Auger/Conveyor Drive ...............................................................C-48
Conveyor Chain and Bar ..............................................................................................C-28
Conveyor Drive Shaft and Sprockets............................................................................C-53
Conveyor Floor Plates ..................................................................................................C-34
Cylinder, Truck Hitch (see Hydraulics)
Drive Assembly, Auger/Conveyor..................................................................................C-37
Drive Shafts and Sprockets, Conveyor..........................................................................C-53
Feeder Drive (Auger/Conveyor Drive Assembly)..........................................................C-37
Floor Plates, Conveyor .................................................................................................C-34
Flow Gates, Power .......................................................................................................C-17
Guard Extensions, Auger and Tunnel ...........................................................................C-61
Hopper Overflow Guards ..............................................................................................C-15
Hopper Sides/Wings (Hinge Rebuild) ...........................................................................C-13
Material Level Indicator, Optional .................................................................................C-71
Mixer/Agitator, Optional ................................................................................................C-68
Mixer/Agitator Pump (see Hydraulics)
Mixer/Agitator Motor (see Hydraulics)
Optional Material Level Indicator ..................................................................................C-71
Optional Mixer/Agitator .................................................................................................C-68
Optional Truck Hitch Assembly .....................................................................................C-23
Oscillating Push Roller Assembly .................................................................................C-21
Overflow Guards, Hopper..............................................................................................C-15
Planetary Drive, Auger/Conveyor Motor .......................................................................C-44
Power Flow Gates ........................................................................................................C-17
Power Flight Auger Cylinder (see Hydraulics)
Pump, Mixer/Agitator (see Hydraulics)
Push Roller Assembly, Oscillating ................................................................................C-21
Shafts, Augers and Bearings ........................................................................................C-58
Side Arms (see Screed)
Side Extensions and Overflow Guards, Hopper ...........................................................C-15
Side Wings, Hopper ......................................................................................................C-13
Sprockets and Chain Case, Auger/Conveyor ...............................................................C-48
Sprockets and Drive Shaft, Conveyor...........................................................................C-53
Truck Hitch Assembly, Optional ....................................................................................C-23
Truck Hitch Cylinder (see Hydraulics)
Tunnel and Auger Guard Extensions ............................................................................C-61
Wings/Sides, Hopper ....................................................................................................C-13
C-2
SAFETY PRECAUTIONS CAUTION

Remove one auger segment at a time. Be
careful not to drop auger segments; they are
WARNING cast Ni-Hard and very brittle.
Do not adjust auger/conveyor drive chains
when engine is operating. Injury could result if CAUTION
machine moves. Install one auger segment at a time. Be care-
ful not to drop auger segments; they are cast
WARNING Ni-Hard and very brittle.
Do not stand in hopper or on conveyors when
engine is operating. Injury could result if CAUTION
machine moves. Do not pinch the feed control paddle or Ultra
3s sensor wire. Do not give the wire too much
WARNING slack so it becomes entangled in the augers.
Stay away from augers when engine is oper-
ating. Injury could result if augers move.
C-3
MATERIAL HANDLING SYSTEM at the front of the hopper helps reduce material spills
between the truck and paver. An optional mixer agita-
THEORY OF OPERATION tor assembly (5) is available to re-mix paving material
immediately before it is conveyed past the flow gates.
The highway class paver/finisher delivers bituminous The flow gates (6) regulate material flow through
base, binder and surface course mixes, cement or each conveyor tunnel to the augers. The L.H. and
lime stabilized sub-base and graded aggregate R.H. flow gate switches are used to hydraulically
materials through a material handling system to the adjust the height of the flow gates to increase or
screed. The major components of the material decrease the amount of paving material being deliv-
handling system are described below. ered to the augers. The flow gate openings should be
coordinated with the paving speed and the width of
The push rollers (1) are located at the front of the paving on each side of the machine to obtain consis-
paver. They provide low friction load bearing contact tent head of material across the entire screed.
between the paver push plate and truck wheels. All
machines are either equipped with a standard oscillat- The conveyor chain and drag bar assemblies (7)
ing push roller assembly or an optional truck hitch. move paving material from the hoppers to the augers.
The oscillating push roller assembly compensates for They are powered by independent L.H. and R.H.
minor misalignment of the truck. The optional hydrostatic drives which simultaneously drive the
hydraulically operated truck hitch retains the truck respective L.H. and R.H. augers. All conveyor bear-
against the paver until released by the paver opera- ings have seals to keep hot asphalt from entering and
tor. are permanently lubricated, requiring no greasing.
The conveyor floor plates (8) are positioned by retain-
The hopper receives paving material from the truck ing slots and clamped in place by the center chain
and acts as a flow bin for transfer of paving material covers. The rear curved conveyor floor plates (9) are
from the truck to paver. The hopper wings (2) bolted in place. The conveyor floor plates require
hydraulically fold to dump paving material from the replacement when worn by abrasion.
outer areas of the hopper onto the conveyors. An
adjustable height apron (3) with overflow guards (4) The augers (10) distribute paving material along the
1 4 2 7 5 6 10
11
12
3
1 2 8 8 9
C-4
entire length of the screed. Ground clearance of the

entire auger system is hydraulically adjustable from
4-1/2" to 9-1/2" (114 mm to 241 mm). All auger bear-
ings have seals to keep hot asphalt from entering and
are permanently lubricated, requiring no greasing.
Auger drives operate simultaneously with the respec-
tive L.H. and R.H. conveyors. A unitized auger/con-
veyor drive assembly (11) on all machines allows the
entire rear section (feeder drive assembly) to be
removed for service.
The optional hydraulically extendible Powerflight

augers replace the standard auger and tunnel
arrangement and are used in conjunction with either
the 3/6 hydraulic screed extensions, OmniScreed II or
OmniScreed III (12). Their independent L.H. and
R.H. extension and retraction are synchronized with
the screed extensions and are operated simultane-
ously by the screed extension switches on the screed
control boxes. A separate auger extension switch is
also included on each side of the screed which allows
the screed operator to change the relationship
between the respective augers and screed exten-
sions. It extends or retracts the auger and tunnel
assembly to increase or decrease the distance
BK-195
between the end of the auger and the edger plate.
The auger can be held stationary while the screed FEED SENSOR MOUNTING HARDWARE,
moves out by holding the auger extension switch IN TELESCOPING TUNNELS
while holding the screed extension switch OUT.
Mounting of the material feed sensors on the ends of

the telescoping tunnels will produce the most direct
control over material level when using Powerflight
augers. It will stop auger rotation and material deliv-
ery when the augers are retracted in advance of
screed retraction.
A second choice for mounting of feed sensors is on

the edger plate supports. The auger can still be
moved independent of the screed. However, the
sensor at the extended edger plate will still call for
material. The auger override switch can be used to
reduce material levels.
BK-68
FEED SENSOR, EDGER PLATE
C-5
MATERIAL HANDLING SYSTEM

MAINTENANCE AND SERVICE
A properly functioning material handling system is
essential in the paving process. To ensure machine
availability in top working condition, preventive main-
tenance must be performed before work begins.
Preventive maintenance begins with inspection.
Systematic inspection may reveal damage that, if not

corrected, may result in serious damage or failure.
Any problems revealed during pre-service inspection
must be reported to the shop foreman or service
manager.
• Keep it clean: Dirt, grease, oil and debris only get

in the way and may cover up a serious problem.
BK-69
Clean as you work and as needed. Use cleaning
solvent to clean metal surfaces and soap and
STRAIGHT END ROD MOUNTING water to clean rubber or plastic material. Use sol-
vent to soften asphalt and a scraper, chisel and
pick to remove the asphalt. Be sure to stress the
importance of daily wash-down to the operator.
The material handling system, especially the pow-
erflight augers, needs to be washed down after
paving each day. Refer to the Operator’s Manual
for correct procedures.
• Bolts, nuts and screws: Check that they are not

loose, missing, bent or broken. Look for chipped
paint, bare metal or rust around bolt heads.
Tighten any that are loose and torque to specifi-
cation.
• Welds: Look for loose or chipped paint, rust or

gaps where parts are welded together. If you find
a bad weld, report it to your supervisor immedi-
ately.
• Electric wires and connectors: Look for cracked

or broken insulation, bare wires and loose or bro-
ken connectors. Tighten loose connections and
make sure wires are in good condition.
• Hose and fluid lines: Look for wear, damage and

leaks. Make sure clamps and fittings are tight.
BK-175 Wet spots show leaks, of course, but a stain
90º END ROD MOUNTING around a fitting or connector can also mean a
leak. If a leak comes from a loose fitting or con-
nector, tighten it. If something is broken or worn
out, either correct it or report it to your supervisor.
The above photos show two possible mounting posi- • Inspect the auger/conveyor drive assembly: Pay
tions for the Ultra 3S sensor from the edger plate. particular attention to the hydraulic lines, plane-
tary drives, auger/conveyor drive chains and
auger bearings.
C-6
MATERIAL HANDLING SYSTEM 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 inspections 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 accurs and then locate the defective
component.
TROUBLESHOOTING GUIDE
AUGER/CONVEYOR WILL NOT OPERATE – ALL MACHINES
PROBLEM CAUSE(S) REMEDY(S)
L.H. & R.H. 1. Operator error/ 1. Engage clutch. Check that hydraulic fluid level in
system(s) will not lack of proper tank is adequate and all other functions on the
operate in MANU- maintenance. machine operate properly.
AL or AUTO.
2. Operator error. 2. Check switch position on opposite operator’s
console. Isolate to L.H. or R.H. side of machine.
3.Open electrical 3. Check voltage and continuity of manual override

circuit. switches on screed control consoles. Isolate to
tractor or screed, L.H. or R.H. side. Replace
switch(es).
4. Loose 4. Check L.H. and R.H. console wiring harness

connection. connections at Electrical Junction Box.
5. Circuit breaker 5. Check continuity of “console” circuit breaker in

faulty. electrical junction box. Isolate circuit problem or
replace circuit breaker (15 amp.)
C-7
MATERIAL HANDLING SYSTEM TROUBLESHOOTING (CONTINUED)
L.H. & R.H. 6. Loose 6. Check screed electrical connections to tractor on

system(s) will not connection. rear bulkhead. Isolate circuit problem to L.H. or
operate in MANU- R.H. side of screed.
AL or AUTO.
7. Open electrical 7. Check voltage and continuity of auger switches in
circuit. operator’s consoles for bad terminal connections.
8. Potentiometer 8. Check auger speed potentiometer in screed con-

faulty/wiring trol consoles for continuity and resistance (150
faulty. Ohms). Check for faulty wiring. Repair wiring.
Replace potentiometer.
9. Force motor 9. Check voltage, resistance and “null” at force

on auger motor(s) on auger pump(s). See Electrical section.
pump(s) faulty. Reset “null,” cross-substitute. Replace force motor.
10. Force motor 10. Check spool and sleeve assembly on auger
contaminated pump(s) for clogging and wear. Clean contaminat-
or worn. ed components. Replace worn components.
11. Feed sensor(s) 11. Check feed sensors (rubber paddles or Ultra 3s)
faulty/loose and related circuits for function, voltage, continuity
connections/ and terminal connections. Jump across pins E and
open electrical F in screed connectors on tractor at rear bulkhead
circuit. to isolate problems in sensors. Cross-substitute
sensors. Repair wiring or replace sensor(s).
12. Auger pump(s) 12. Check auger/conveyor pump(s) operating system

faulty/pressure pressure (3000 psi maximum). Inspect pressure
compensator(s) compensator(s) for contamination or broken
faulty, contami- spring(s). Reset or replace pressure compen-
nated or sator(s). See Hydraulics section.
misadjusted.
13. Charge 13. Check charge filter for clogging. Clean or replace
pressure filter charge pressure filter.
plugged.
14. Pilot control fil- 14. Check pilot control filter(s) on auger pump(s).
ter(s) plugged. Clean or replace filter(s).
15. Charge 15. Check charge pressure from traction pump(s).

pressure low. Should be 350 PSI. Reset charge pressure.
Replace charge pump(s).
C-8
L.H. & R.H. 16. Leaking 16. Check all hydraulic lines and fittings for breaks or
system(s) will not hydraulic leaks. Repair or replace line(s) or hose(s).
operate in MANU- line(s).
AL or AUTO.
17. Auger pump(s) 17. Check auger/conveyor pump(s) for proper pres-
worn or faulty. sure and output flow. Repair or replace pump(s).
See Hydraulics section.
18. Auger/ 18. Check auger/conveyor motor(s) for function and

conveyor internal leakage. Repair or replace motor(s).
motor(s) worn
or faulty.
19. Auger/ 19. Check auger/conveyor planetary for function.

conveyor Repair or replace.
planetary
faulty.
20. Mechanical 20. Check function of feeder drive system. Retension

failure within drive chain(s). Repair as needed.
feeder drive
system.
C-9
AUGER/CONVEYOR WILL NOT OPERATE IN AUTO, BUT WILL OPERATE IN MANUAL
L.H. & R.H. 1. Material feed 1. Check material feed sensor(s) (rubber paddle(s)
system(s) will not sensor(s) or Ultra 3s) for function and voltage output. (Mat-
operate in AUTO. faulty. Kontrol paddle: 4V, 8V & 12V) (Ultra 3s: infinite,
3 - 9V. See rear of Section A in Ultra 3s Operator’s
Manual for test details.) Cross-substitute sensors
to isolate problem. Repair or replace as needed.
2. Motion/brake 2. Check motion/brake circuit breaker within

circuit breaker electrical junction box. Check for short within
faulty/shorted circuit. Repair wiring. Replace motion/brake
electrical circuit breaker.
circuit.
3. Motion relay 3. Check function of motion relay within electrical

faulty. junction box. Repace motion relay.
4. Open or 4. Check continuity and voltage of circuit. Isolate

shorted problem within motion circuit wiring. Repair
electrical wiring. Replace wire harness(es).
circuit.
5. Motion limit 5. Check function of motion limit switch in L.H.

switch faulty or traction control console. Adjust. Replace limit
misadjusted. switch.
C-10
SYSTEM(S) RUN SLOW OR ERRATICALLY
L.H.or R.H. auger/ 1. Drive train 1. Adjust clutch. Replace clutch driving plate (3-pc.).
conveyor runs slow clutch slipping. Repair or replace components as needed.
or erratically.
2. Faulty or 2. Check function of respective L.H. or R.H. com-
contaminated pensator on auger/conveyor pump for sticking or
compensator. contamination. Clean. Replace spool assemblies
or spring. Adjust compensator. Replace compen-
sator.
3. Main hydraulic 3. Check main hydraulic filter(s) for clogging and

filter(s) tight seal(s). Check for foaming within hydraulic
clogged or tank (air intrusion). Replace filter(s).
seal(s) not
tight.
4. Strainers in 4. Check strainer(s) within hydraulic tank for clog-

hydraulic tank ging. Clean strainer(s). Replace strainer(s).
clogged. Replace main hydraulic filter(s).
5. Charge 5. Check traction pump(s) for proper charge pres-

pressure low. sure to auger/conveyor pump(s) pilot control(s).
Should be 350 psi. See Hydraulic section.
6. Charge 6. Check charge pressure filter between traction

pressure filter pump(s) and auger/conveyor pump(s) for clog-
clogged. ging. Clean filter. Replace filter.
7. Pilot control 7. Check auger/conveyor pump(s) pilot control fil-

filter(s) ter(s) for clogging. Clean filter(s). Replace filter(s).
clogged.
8. Pumps 8. Check all pumps for cavitation (air intrusion within

cavitating. suction lines). Hydraulic tank will contain foam if
air is present. Tighten or replace suction line(s).
Check and refill hydraulic fluid in hydraulic tank.
C-11
SYSTEM(S) RUN WITHOUT MATERIAL, BUT STALL UNDER LOAD
Auger/conveyor 1. Pump(s) or 1. Check pump(s) for proper pressure and flow out-
stalls under load of motor(s) worn put. Check motor(s) for internal leakage. Check
material. or leaking. for leaks within system lines and fittings. Repair
or replace as needed.
2. Pump(s) 2. Check auger/conveyor pump(s) compensator

compensator(s) relief setting. Should be 3000 psi. Reset compen-
worn or sator. Check compensator(s) for worn parts or
contaminated. contamination. Repair or replace as needed.
3. Bearing(s) 3. Check for failed auger or conveyor bearings.

failure. Replace bearings as needed.
4. Mechanical 4. Check for mechanical binding or restriction within

binding or the conveyor chain assemblies, feeder drive sys-
restriction. tem or auger shaft assemblies. Repair or replace
components as needed.
5. Auger/convey- 5. Check function of auger/conveyor planetaries.

or planetary(s) Repair or replace as needed.
worn or failed.
6. Mechanical 6. Check for mechanical failure in (broken drive

failure within chain) within feeder drive assembly. Repair or
feeder drive replace as needed.
assembly.
C-12
HOPPER SIDES/WINGS (HINGE REBUILD)

This procedure covers:
✓ Removal Inspection/Specification ✓ Installation

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

• Battery disconnected or battery master disconnect ✓ None ✓ None
switch turned OFF.
• Machine blocked to prevent movement.
• Hopper wings lowered (optional).
• Overflow guards removed (optional).
C-13
HOPPER SIDES/WINGS Step 3:

Grind all surfaces to obtain good alignment of
(HINGE REBUILD) new hinge tubes.
REMOVAL INSTALLATION
Step 1:
Step 1:
Support hopper wing and hopper hinge in posi-
Install new hinge tubes on hinge pin.
tion by clamping on wing with overhead crane.
Step 2:
Install hinge pin with tubes in position between
frame and side/wing.
IMPORTANT
Always tack weld before you finish weld to
check alignment.
a. Clamp hinge in place on frame.

b. Weld every other hinge tube (3) to the frame
(4). (Tack weld first.)
c. Support hopper wing (5) against the hinge (in
position).
d. Weld every other hinge tube to the hopper
wing. (Tack weld first.)
e. Tack weld the hinge pin at the front end to
maintain position.
BK-196
Step 2:
Remove hinge tube and pin. 43
a. Remove tack weld (1) at end of hinge pin.
b. Remove pin.
c. Disconnect cylinder.
d. Swing hopper wing away from frame.
e. Burn off hinge tubes (2) from frame and
hopper wings.
2
65 5
4
BK-55
2965-32
C-14
HOPPER APRON AND OVERFLOW GUARDS



• Machine blocked to prevent movement. ✓ None ✓ None
• Hopper wings lowered.
• Battery disconnected or battery master disconnect
switch turned OFF.
C-15
HOPPER APRON AND Step 2:

Remove bolts on the apron overflow guard in the
OVERFLOW GUARDS center of the hopper (3).
Step 3:
REMOVAL Remove the overflow guards.
Step 1:
Remove bolts (1) on overflow guards (2) on both
sides of the hopper.
INSTALLATION
Install all overflow guards by reversing removal proce-
dures.
2 3
2713-14
C-16
POWER FLOW GATES

✓ Removal ✓ Inspection/Specification ✓ Installation

✓ Disassembly Assembly Adjustments
Special Cleaning ✓ Component Test ✓ Equipment Preparation

• Flow gates lowered halfway and blocked in position.
switch turned OFF.
• Front deck plates raised or removed.
• Engine housing raised or removed.
• ORS caps and plugs for hydraulic lines and fittings.
C-17
POWER FLOW GATES Step 3:

Disconnect the hydraulic cylinders (4).
a. Disconnect hydraulic lines at each cylinder.
REMOVAL Cap and plug.
b. Remove cylinder pin (5)
NOTE c. Lay the hydraulic cylinder out of the way.
Flow gates must be fully lowered or blocked
up so they do not fall down when the
hydraulic flow gate valves are disconnected.
Step 1:
Disconnect the material indicator switch (1, if
equipped). 5
4
1 2783-9
Step 4:
Remove the hydraulic flow gate valve (6).
a. Disconnect hydraulic lines to each flow gate
cylinder. Cap and plug.
b. Remove two mounting bolts (7).
c. Lay the hydraulic valve out of the way.
2783-16
Step 2:
Remove the L.H. and R.H. flow gate depth gauges.
a. Remove mounting bolts (2) securing depth 6
gauges (3) to the brackets.
b. If deck plate has been removed, lift depth
gauges away from the mounting brackets. 7
c. If deck plate remains on the machine, slide the
depth gauges down and out of the machine.
3 7
2783-11
2783-9
C-18
Step 5: INSTALLATION
Remove the center flow gate guide and separation
bar. Step 1:
a. Remove mounting bolts. Install the L.H. and R.H. flow gates (9).
b. Remove the guide and separation bar (8). a. Lift flow gates into the machine.
b. Slide flow gates toward the outside of the
Step 6: machine.
Remove the L.H. and R.H. flow gates.
a. Slide flow gates (9) toward the center. Step 2:
b. Lift flow gates up and out of the machine. Install the center flow gate guide and separation
bar.
a. Install the guide and separation bar.
b. Install mounting bolts.
9
9
8
8
2783-9
Step 3:
2783-9
Install the hydraulic valve flow gate valve (6) by
reversing removal procedures.
DISASSEMBLY/ASSEMBLY
Step 4:
Refer to the Hydraulics section on pages D-39 to Install the hydraulic flow gate cylinders (4) by
D-46 for more information if further disassembly of reversing removal procedures.
the hydraulic flow gate valve is required.
COMPONENT TEST 6
Step 1:
Start machine.
Step 2: 4
Operate flow gate (to raise or lower) by using the
flow gate switches on L.H. or R.H. operator’s
console.
2783-11
C-19
Step 5: EQUIPMENT PREPARATION

Install the L.H. and R.H. flow gate depth gauges.
a. Slide the depth gauges (3) into the machine Step 1:
and through the opening in frame. Connect battery or turn battery master disconnect
b. Install mounting bolts securing the depth switch ON.
gauges to their mounting brackets.
Step 2:
Operate flow gates.
a. Turn on main power.
b. Start machine.
c. Raise and lower flow gates.
3
Step 3:
Lower the deck plates and engine housing.
2783-9
C-20
OSCILLATING PUSH ROLLER ASSEMBLY
Removal ✓ Inspection/Specification Installation

✓ Disassembly ✓ Assembly Adjustments

• Front hopper apron raised.
switch turned OFF.
C-21
OSCILLATING PUSH ROLLER

ASSEMBLY 4
DISASSEMBLY
Step 1:
Remove the oscillating push roller shaft.
a. Loosen set screws (1) on each side of roller.
1
2964-11
INSPECTION
Inspect the oscillating push roller shaft, bearings and
rollers for wear or failure. Replace if necessary.
ASSEMBLY
Step 1:
2964-9 Position the roller in the assembly.
a. Install bearings at the end of the roller.
b. Attach lifting device to roller to prevent it from b. Support roller (5) between the two mounting
falling. brackets.
c. Loosen the bearing set screws (2) in the
bearing collar (3). (Two set screws at each NOTE
end of shaft.) When installing new rollers, install a snap ring
d. Drive the shaft out at the inner bearing. on each side of each roller.
e. At the outer bearing, grasp the shaft and pull
it all the way out.
2964-9
2964-9 Step 2:
Install the shaft.
Step 2: a. With the roller in position, push shaft through
Remove the roller bearings. the roller until flush with the mounting bracket.
a. Lower roller to the ground. b. Center roller between brackets and tighten set
b. Remove bearings (4) from end of roller. screws on each side of the roller.
C-22
OPTIONAL TRUCK HITCH ASSEMBLY

Removal ✓ Inspection/Specification ✓ Installation

Special Cleaning Component Test ✓ Equipment Preparation

• Front hopper apron raised.
• Truck hitch retracted.
• Catch container for hydraulic fluid (3 qts., 2.8 L).
• Optional: Raise machine to provide access.
switch turned OFF.
C-23
OPTIONAL TRUCK HITCH

ASSEMBLY
DISASSEMBLY
4
Step 1:
Remove side roller arm. 3
a. Partially extend both sides of the truck hitch
tube. (Clamp one side and partially extend the
opposite side. Repeat for the other side.)
b. Remove four bolts (1) at the end of the tube.
c. Extend shaft enough to grip shaft.
d. Remove nut (2) at the end of the cylinder rod.
2964-16
NOTE
Insert a screwdriver or square punch into the NOTE
notch at the end of the cylinder rod to prevent To service the double-acting hydraulic cylin-
it from spinning in the tube as you turn the der, see the “Truck Hitch Cylinder” section in
nut. the Hydraulics module on pages D-55 to
D-58
Step 2:
Disassemble truck hitch hub roller, if necessary.
a. Loosen the retaining bolt (5) at the top of the
roller.
b. Remove the snap ring (6).
c. Remove the allen bolt and washer.
1
5
2
2964-14
e. Remove the end plate cover (3).

f. Lift arm assembly (4) out off the shaft.
2964-4
19 10
9
7
8
14
12
1
15
3
4 5 17 11
BK-176A
C-24
d. Remove the hub roller (7). NOTE

e. Remove the self-aligning bushing (8) and Make sure to remove the bolt, collar and
inspect for wear. Replace if worn or damaged. wear washer from the truck hitch tube.
8 6 11
12
2964-5
Step 3: 2964-17
Disassemble the side rollers (9), if necessary. Step 6:
a. Remove two allen bolts holding the roller in Disconnect hydraulic hoses at the fittings (13) on
place. the assembly. Cap and plug both lines.
b. Remove the roller with bearings.
13
2964-8 2964-22
Step 4: Step 7:
Remove push roller (10), if necessary. (Refer to Remove the truck hitch frame (14) from the
the “Oscillating Push Roller Assembly” proce- machine.
dures on pages C-21 to C-22.) a. Attach two slings around the truck hitch.
b. Remove four mounting bolts (15) on each side
of the mounting bracket.
c. Pull the truck hitch frame off the machine and
10 lay it on the ground.
14
15
2964-9
Step 5:
If necessary, remove the roller retaining bolt (11)
and slide (12) from each side of the truck hitch
frame.
2964-26
C-25
Step 8: Step 10:

Disconnect the hydraulic fittings at the hydraulic OPTIONAL: Remove the truck hitch frame at the
cylinder. pivot pin so that the mounting brackets remain on
a. Remove the manifold cover (16) for access to the machine.
the hydraulic tubes and fittings. a. Block or chain-support the truck hitch frame.
b. Remove the nut, bolt and washer at the end of b. Remove two bolts (18) from the top of the
the manifold cover. truck hitch frame
c. Disconnect the hydraulic tubes at the center. c. Remove the cotter pin from the bottom of the
Remove, cap and plug. pivot pin (19).
d. Remove fittings from the hydraulic cylinder.
16
18
2964-27
2964-26
Step 9:
Remove the double-acting hydraulic cylinder as a d. Drive the pivot pin through the frame. Inspect
complete assembly. for wear and replace if worn or damaged.
e. Lower the truck hitch frame to the ground or
IMPORTANT place on an elevated work surface. Inspect
Both side roller arms must be removed before slide surfaces for damage and replace if
accessing/removing the hydraulic cylinder. necessary.
f. Remove the set screws on the pivot pin frame
a. Remove two bolts securing the cylinder to the to remove bushings. Replace bushings if worn
truck hitch frame. or damaged.
b. Pull the double-action cylinder (17) from one
end of the frame.
17
19
2964-34
2964-32
C-26
INSPECTION EQUIPMENT PREPARATION

Inspect the hub roller bearings, slide bushings and Step 1:
push roller bearings for wear or damage. Replace if Connect battery or turn battery master disconnect
necessary. switch ON.
Inspect the hydraulic cylinder and seals for leaks or Step 2:

wear. Repack with new seals if necessary. Lower hopper apron.
Inspect the hydraulic cylinder rod. If the rod is bent, Step 3:

replace the entire hydraulic cylinder. Test truck hitch assembly.
a. Start engine.
b. Operate truck hitch. Extend and retract truck
ASSEMBLY/INSTALLATION hitch several times.
Install the optional truck hitch assembly by first Step 4:

reversing the removal procedures. Once the assem- Check hydraulic fluid level. Add more fluid if
bly is in position on the machine, assemble the truck necessary.
hitch by reversing the disassembly procedures.
IMPORTANT
Apply thread sealant to the roller retainer for
the slide.
C-27
CONVEYOR CHAIN AND BAR


✓ Disassembly ✓ Assembly ✓ Adjustments

• Screed removed (optional). ✓ 9/16" x 3" bolts for ✓ None
• Machine raised at least 2 feet (60cm). conveyor chain
• Machine blocked to prevent movement. (2 bolts per chain)
switch turned OFF.
C-28
CONVEYOR CHAIN AND BAR NOTE

Before driving the pins out, secure the chain
to the undercarriage with a come-along or
other adequate tie so it doesn’t fall down
REMOVAL when the link pin comes loose.
Step 1: d. Drive out link pins on each side of the chain.
Break conveyor chain (1).
NOTE
IMPORTANT Use 9/16" x 3" bolts to replace the link pins
If you will be installing new conveyor chains when breaking the chain to keep the chain
on the machine, first slacken the conveyor together as you move the chain to the back of
idler bearings before removing the old chain the machine. To make bolts easier to remove
assemblies from the machine. at the conveyor sprockets, position the bolt
heads so they face the inside part of the
a. Lift hopper apron. chain.
b. Loosen chain tensioner bolts (2) at the front of
the hopper. Step 2:
Remove the conveyor center chain covers (5), if
necessary.
NOTE
Remove chain covers only if replacing floor
1 plates or removing the auger/conveyor drive
assembly (feeder unit).
a. Remove bolts from the undercarriage that

secure the front and rear center conveyor
chain covers (three bolts in rear; four in front).
b. Pull the center chain covers out of the
machine.
2
2713-18 6
c. Pull cotter pins (3) in link pins (4) from the
conveyor chain beneath the undercarriage.
NOTE
Keep enough tension on the chain to allow 5
you to remove the cotter pins by striking them
with a hammer.
2727-6
1 Step 3:
Remove the conveyor outer chain covers (6), if
necessary.
NOTE
4 plates or removing the auger/conveyor drive
3
2727-3
C-29
a. Remove six bolts inside the conveyor tunnel

that secure each rear outer chain cover (one 7
on each side) and three bolts on each side of
the hopper that secure each front outer chain
cover.
b. Pull the front and rear outer chain covers out
of the machine.
Step 4:
Remove the conveyor chains from the back of the 8
machine.
a. Start engine and slowly run the master link
(the link with the 9/16" bolts in it) to the con-
veyor sprocket at the back of the machine.
b. Remove bolts to break the chain and pull the
chain out from the back of the machine.
2713-18
IMPORTANT c. Loosen chain tensioner bolts at the front of the

To operate the auger/conveyor circuit when hopper (9).
the screed is removed, jumper wires must be
connected between terminals E and F at both
the L.H. and R.H. rear screed receptacles.
2713-21
d. Drive out link pins on each side of the chain

2783-23 with the links positioned immediately behind
the idler bearing from the under side of the
NOTE machine.
The conveyor chains and bars can also be
removed from the front of the machine.To Step 2B:
perform this procedure, follow Step 1B Remove the conveyor center chain covers (10), if
through Step 4B below. necessary.
NOTE
Step 1B:
Break conveyor chain.
plates or removing the auger/conveyor drive
IMPORTANT
If you will be installing new conveyor chains
on the machine, first slacken the conveyor
idler bearings before removing the old chain
assemblies from the machine.
a. Lift hopper apron.

b. Pull cotter pins (7) in links (8) immediately
after idler bearing.
C-30
11
10
DIRECTION OF CHAIN TRAVEL BK-61A

TOWARD REAR OF MACHINE
2727-6
Step 3B:
INSPECTION
Step 1:
necessary.
Check for missing or broken cotter pins.
NOTE
NOTE
Refer to the Wear Check Manual for details.
Step 2:
Inspect the conveyor bars for wear or damage.
Replace if necessary.
that secure each rear outer chain cover (one
Step 3:
Inspect the conveyor chain links for wear or
cover.
damage. Replace if necessary.
of the machine.
Step 4:
Inspect wear inserts or lower chain guides at
Step 4B:
bottom of undercarriage for wear or damage.
Pull the chain forward from under the machine.
Replace wear inserts.
Use a lift truck. Allow enough space for the chain
to be completely removed.
IMPORTANT ASSEMBLY
Do not pull chain from the hopper. Pull from
below the machine, in the direction of chain Install conveyor bar subassemblies.
travel. a. Install conveyor bar with rollers.
b. Install the cotter pins and links on each side of
the conveyor bar subassembly.
DISASSEMBLY
Remove conveyor bar subassemblies.
a. Remove the cotter pins and links on each side
of the conveyor bar subassembly.
b. Remove conveyor bar with rollers.
2713-21
C-31
Step 2:
Connect the conveyor chain.
a. Install link pins.
b. Install cotter pins.
BK-61
INSTALLATION
Step 1:
Install chain in the machine (from rear to front).
2727-3
a. Lay chain on the floor at the rear of the
machine with wide end in links toward front. Step 1B:
b. Attach a cable to the chain and use a fork lift OPTIONAL: Install chain in the machine (from
truck or come-along to pull the chain through front to rear).
the lower chain guides towards the hopper. a. Lay chain on the floor in front of the machine
c. Bring chain over the front idler assembly and with wide end in links toward rear.
towards the conveyor drive sprockets. b. Bring the chain up over the front idler shafts
d. Engage chain in conveyor drive sprockets and (1).
feed so the broken link is underneath the c. Attach a cable to the chain and use a fork lift
machine in the middle. truck or come-along to pull the chain through
the machine to the conveyor shaft sprockets.
IMPORTANT d. Feed the chain onto the conveyor shaft
The chain must go over the lower chain sprockets.
guides on the undercarriage of the machine.
Make sure when pulling the chain to the front IMPORTANT
of the machine that the cable is routed above The chain must go over the lower chain guide
the lower chain guides. on the undercarriage of the machine. Make
sure when pulling the chain to the front of the
IMPORTANT machine that the cable is routed above the
To operate the auger/conveyor circuit when lower chain guide.
connected between terminals E and F at both e. Connect a cable to the chain to pull the chain
the L.H. and R.H. rear screed receptacles. to the front of the machine.
E 1
2783-23
2713-21
C-32
CAUTION IMPORTANT
Fork lift operator must use caution when Adjust both sides of conveyor equally to pro-
pulling the chain through the tractor. The duce a true-running, non-binding conveyor.
chain should not be pulled faster than the
conveyor motor speed or damage to the a. Turn the conveyor chain tensioner bolts to
motor will result. obtain the 5" minimum ground clearance.
b. Check that L.H. and R.H. chain tensioner bolts
f. Connect battery or turn the battery master dis- are adjusted equally.
connect switch ON. Using a fork lift truck, run
the conveyor and pull the chain forward slowly.
IMPORTANT
To operate the auger/conveyor circuit when
5" Min.
E
F
BKM-7402
Step 3:
Lower the front hopper apron.
2783-23 EQUIPMENT PREPARATION

Step 3: Step 1:
Install the inner conveyor chain covers if Test the conveyor for proper operation.
removed.
a. Slide chain covers (front and rear) into the IMPORTANT
machine. To operate the auger/conveyor circuit when
b. Install bolts from undercarriage that secure the the screed is removed, jumper wires must be
front and rear conveyor inner chain covers. connected between terminals E and F at both
Step 4:
Install the outer conveyor chain covers if a. Start engine.
removed. b. Run the conveyor at different speeds to check
a. Slide the outer chain covers (two in front and the chain function.
two in rear) into the machine. c. Remove the jumper wire (if the screed is not
b. Install six bolts on each side of the conveyor attached).
tunnel that secure the rear outer chain covers
to the machine frame and three bolts on each Step 2:
side of the hopper that secure the front outer Attach the screed if it had been removed.
chain covers.
ADJUSTMENTS
Step 1:
Raise the front hopper apron.
Step 2:
Adjust the conveyor idler bearings.
C-33
CONVEYOR FLOOR PLATES



• Flow gates completely raised or removed. ✓ None ✓ None
• Screed removed (optional).
• Hopper apron removed.
• Machine raised at least 2 feet (60cm)
and blocked to prevent movement.
C-34
CONVEYOR FLOOR PLATES Step 4:

Remove the conveyor floor plates (1) from the
front hopper.
REMOVAL a. Slide the front conveyor floor plate toward the
center of the machine so the interlocking tabs
NOTE (2) clear the notches (3) in the hopper frame.
Floor plates have a clamp-in design which b. Lift the floor plates out of the machine.
eliminates most of the mounting bolts
beneath the conveyor floor plates. The center
chain covers clamp the conveyor floor plates
in place.
3
Step 1: 1
Remove all conveyor chain covers. (See
“Conveyor Chain and Bar” on the preceeding
pages for this procedure.)
2
2727-8
Step 5:
Remove the rear curved floor plates (4).
NOTE
The rear center chain cover must be removed
or pushed forward about 1 foot before the
rear curved floor plate can be removed.
2727-6
a. Remove five countersunk allen bolts from the
Step 2:
rear curved plate.
Remove the conveyor chains. (See “Conveyor
b. Lift the rear curved floor plate out of the
Chain and Bar” on the preceeding pages for this
machine.
procedure.)
2713-21 2727-10
Step 3:
Disconnect battery or turn the battery master
disconnect switch OFF.
C-35
INSPECTION INSTALLATION
Step 1: Step 1:
Inspect the conveyor floor plate extensions (5) for Install conveyor floor plate extensions if removed.
wear or damage.
Step 2:
Install rear curved floor plates in position on the
frame.
Step 3:
Install the rear center chain covers.
Step 4:
Install the front conveyor floor plates.
a. Line up tabs on floor plates with notches in
5 hopper frame.
b. Slide floor plates so that tabs and notches
interlock and prevent the floor plates from
sliding forward or backward.
Step 5:
Connect battery.
2727-14
NOTE Step 6:
Conveyor floor plate extensions must be Install conveyor chain assemblies and chain
removed before removing the feeder drive guard covers. (See “Conveyor Chain and Bar”
assembly. on pages C-28 to C-33 for procedures.)
Step 2: Step 7:
Replace conveyor floor plate extensions, if neces- Install hopper apron.
sary, by removing or burning off mounting bolts
from below. Step 8:
Lower machine to the ground.
Step 3:
Inspect the conveyor chain assemblies and chain
covers for damage or wear. Replace components
as needed.
C-36
AUGER/CONVEYOR DRIVE ASSEMBLY (FEEDER DRIVE)



• Machine blocked to prevent movement. ✓ 9/16" x 3" bolts ✓ None
• Augers lowered. for conveyor chain
• Machine blocked up 2 feet under front and (2 bolts per chain)
rear frame of paver to improve access.
• Hydraulic tank drained to minimize fluid loss
(optional).
• Catch container for hydraulic fluid (5 gal., 19 L).
Note: This procedure requires two people.
C-37
AUGER/CONVEYOR DRIVE IMPORTANT

ASSEMBLY (FEEDER DRIVE) on the machine, first slacken the conveyor
REMOVAL
b. Remove the cotter pins (4) on two conveyor
Step 1: link pins (5) directly across from each other.
Disconnect screed. (See “Screed Assembly” on
pages G-14 to G-16.) NOTE
Keep enough tension on the chain to allow
Step 2: you to remove the cotter pins by striking them
Remove hopper apron. with a hammer.
a. Lift hopper apron (1).
b. Remove four bolts and nuts (2) from the
bottom of the apron (2 on each side).
c. Remove apron from hopper.
5
2
4
2727-3
NOTE
Before driving the pins out, secure the chain
2965-33 to the undercarriage with a come-along or
NOTE other adequate tie so it doesn’t fall down
To remove chain from the back, follow Step 3 when the link pins come loose.
through Step 6. To remove chains from the
front, skip to Step 7. c. Drive out link pins on each side of the chain.
Step 3: NOTE
Disconnect conveyor chains. Use 9/16" x 3" bolts to replace the link pins
a. Loosen chain tensioner bolts (3) at front of when breaking the chain to keep the chain
hopper. together as you move the chain to the back of
the machine. To make bolts easier to remove
at the conveyor sprockets, position the bolt
heads so they face the inside part of the
chain.
Step 4:
Remove the conveyor center chain covers (6), if
necessary.
NOTE
3
2713-21 chain covers (three bolts in rear; four in front).
C-38
b. Pull the center chain covers out of the IMPORTANT

machine. To operate the auger/conveyor circuit when
7 the L.H. and R.H. rear screed receptacles.
6 E
F
2727-6
Step 5:
necessary. 2783-23
NOTE NOTE
Remove chain covers only if replacing floor The conveyor chains and bars can also be
plates or removing the auger/conveyor drive removed from the front of the machine.To
assembly (feeder unit). perform this procedure, follow Step 7 through
Step 10 below.
that secure each rear outer chain cover (one
Step 7:
OPTIONAL: Break conveyor chain to remove
chain from the front.
cover.
IMPORTANT
of the machine.
on the machine, first slacken the conveyor
NOTE
If conveyor chains are to remain on the
machine, skip to Step 11 to remove the feed-
er drive assembly.
a. Pull cotter pins (8) in links (9) immediately
after idler bearing on bottom side.
Step 6:
Remove the conveyor chains from the back of the
machine.
a. Start engine and slowly run the master link 8
(the link with the 9/16" bolts in it) to the con-
veyor sprocket at the back of the machine.
b. Remove bolts to break the chain and pull the
chain out from the back of the machine.
2713-18
C-39
b. Loosen chain tensioner bolts at the front of the a. Remove six bolts inside the conveyor tunnel
hopper (10). that secure each rear outer chain cover (one
cover.
of the machine.
Step 10:
Pull the chain forward from under the machine.
Use a lift truck. Allow enough space for the chain
to be completely removed.
IMPORTANT
Do not pull chain from the hopper. Pull from
below the machine, in the direction of chain
10 travel.
CAUTION
2713-21
Fork lift operator must use caution when
c. Drive out link pins on each side of the chain. pulling the chain through the tractor. The
chain should not be pulled faster than the
Step 8: conveyor motor speed or damage to the
Remove the conveyor center chain covers (11), if motor will result.
necessary.
Step 11:
NOTE Remove the rear curved floor plates (13).
plates or removing the auger/conveyor drive NOTE
assembly (feeder unit). The rear center chain cover must be removed
or pushed forward about 1 foot before the
a. Remove bolts from the undercarriage that rear curved floor plate can be removed.
chain covers (three bolts in rear; four in front). NOTE
b. Pull the center chain covers out of the If conveyor chain remained in the machine,
machine. pull the chain forward to provide access to
the curved plate mounting screws.
a. Remove five countersunk allen bolts from the

12 rear curved plate.
b. Lift the rear curved floor plate out of the
machine.
11
13
2727-6
Step 9:
necessary.
NOTE
Remove chain covers only if replacing floor 2727-10
C-40
Step 12:
Remove the conveyor floor plate extensions (L.H.
plate (14) is removed; R.H plate (15) remains in
position) by removing or burning off mounting
bolts from below.
17
15
14
2727-26
Step 16:
Remove the outer conveyor bearing (18).
a. Remove bolts from the outer conveyor
bearing.
b. Loosen set screws from the bearing to the
2727-14
shaft.
Step 13: c. Remove the bolt and spacer from the outer
Disconnect the hydraulic hoses (16) to the feeder conveyor bearing.
drive. d. Pull bearing off the shaft.
a. Disconnect hydraulic hoses to the auger/con-
veyor motor.
b. Mark, cap and plug all fittings and hoses. 19
18
16
2727-29
Step 17:
Remove the guide bolt and spacer (19) from the
2727-10 kidney-shaped slot of the feeder drive outer plate.
Step 14:
Sling the feeder drive around the tunnel shaft and
take up slack.
Step 15:
Disconnect the auger lift cylinder (17).
a. Remove the cotter key.
b. Remove pin from the clevis of cylinder.
C-41
Step 18:
Remove the feeder drive.
a. Remove four feeder drive mounting bolts (20)
near the conveyor shaft inner bearing. (Two
bolts on each side of the feeder drive.)
20
2727-20
Step 3:
Remove the augers, shafts and bearings, if neces-
sary. (See “Augers, Shafts and Bearings” on
pages C-58 to C-60.)
2727-27
b. Pry the feeder drive away from the frame.

c. Raise the feeder drive assembly and move it
away from the machine.
d. Lower the assembly to the floor.
DISASSEMBLY (OPTIONAL)
NOTE
Disassemble the feeder drive if necessary.
Step 1:
Remove the auger/conveyor drive chains if neces-
sary. (See “Auger/Conveyor Drive Chain and
Sprockets” on page C-48 and “Conveyor Drive
Shaft and Sprockets” on page C-53.)
2727-21
Step 4:
Remove the conveyor shaft, if necessary. (See
“Conveyor Drive Shaft and Sprockets” on pages
C-53 to C-57.)
2727-16
Step 2:
Remove the auger/conveyor motor/planetary
drive, if necessary. (See “Auger/Conveyor
Motor/Planetary Drive” on pages C-44 to C-47.)
2727-27
C-42
ASSEMBLY/INSTALLATION EQUIPMENT PREPARATION

Install the auger/conveyor drive assembly (feeder Step 1:
drive) by reversing the removal procedures. Check fluid in the conveyor planetary drive (1 and
2). Add if necessary.
NOTE
Apply surface sealant to planetary drive NOTE
mounting surface. Apply thread sealant to Check fluid level with augers lowered.
drive mounting bolts. Do not tighten bolts until
chain is tensioned.
NOTE
Turn chain tension adjusting screw until chain 1
has approximately 1/4" (6mm) of total deflec-
tion by hand. Tighten planetary mounting
bolts.
2
3416-16
Step 2:
Start machine and run conveyor to check for
proper operation.
Step 3:
Check hydraulic tank level. Fill if needed.
BK-194A
NOTE
Grease chain if chain case was cleaned (use
three tubes of grease).
NOTE
Inspect wear inserts of lower chain guides at
bottom of undercarriage for wear or damage.
Replace wear inserts prior to installing con-
veyor chain.
C-43
AUGER/CONVEYOR MOTOR/PLANETARY DRIVE



• Augers raised.
• Screed lowered.
• Auger/conveyor motors can be removed or
may remain on unit.
• Planetary drive drained if planetary is to be disassembled.
• Catch container for planetary drive fluid (6 pts., 3 L transmission fluid).
C-44
AUGER/CONVEYOR MOTOR/ a. On the control console, turn the main power

ON.
PLANETARY DRIVE b. Switch the auger control (L.H. or R.H.) to
MANUAL.
c. Stop the auger/conveyor chain when the mas-
REMOVAL ter link (the link with the cotter pins) is located
in the center of the opening.
Step 1:
d. Turn off the machine. Disconnect battery.
Remove rear cover (1) on the auger chain case.
a. Remove three bolts on each side of the cover.
Step 3:
b. Remove cover and set aside.
Remove top cover (2) on the chain case.
a. Remove four bolts securing the cover.
b. Remove the hydraulic hose clamps.
c. Remove the cover.
2727-10
Step 2:
Jog the auger/conveyor to move the chain until
the master link is in the center of the chain case 2727-14
opening. Step 4:
Break the auger/conveyor drive chain.
NOTE a. Loosen the planetary mounting bolts (3). Do
One person should operate the auger/con- not completely remove them at this time.
veyor drive while a second person watches b. Loosen the chain tensioner bolt (4).
for the master link as the chain is run through c. Remove the master link (5) cotter pins.
the chain case.
IMPORTANT
To operate auger/conveyor while the screed
is disconnected, jumper wires must be con-
nected between terminals E and F at both the 3 3
L.H. and R.H. rear screed receptacles.
5
E
F
2727-16
d. Loop mechanics wire through the drive chain

above and below the master link. This will help
keep the chain from falling to the bottom of the
chain case.
2783-23 e. Drive the link pins out to break the chain.
C-45
f. Reinsert one mounting bolt into the chain case IMPORTANT

and tie off the top part of the drive chain. Make sure you have drained the planetary
g. Tie off the bottom part of the drive chain. drive before detaching it from the motor.
Step 5: d. Optional: Remove the drive sprocket (8) if

Remove the auger/conveyor motor (6). desired.
e. Inspect and/or service the planetary. Refer to
NOTE Appendix C-1 for a listing of vendor publica-
The auger/conveyor motor and planetary tions.
drive may be removed as unit or indepen-
dently. If removing them independently, first NOTE
drain the planetary drive of transmission fluid. For reassembly, all removed gaskets must be
replaced with new gaskets for proper bearing
a. Disconnect hydraulic lines to the motor. Plug load and seal.
and cap lines.
b. Remove four mounting bolts that mount the Step 7:
motor to the planetary. Clean the chain case interior if desired.
c. Pull motor straight out from planetary. Be care-
ful not to damage splines on the motor shaft.
INSTALLATION
Install auger/conveyor motor/planetary drive by
reversing the removal procedures.
IMPORTANT
If hydraulic motor was removed, fill with
hydraulic fluid.
6 NOTE
Apply surface sealant to the planetary drive
mounting surface. Apply thread sealant to the
drive mounting bolts.
NOTE
Turn chain tension adjusting screw until chain
has approximately 1/4" (6mm) of total deflec-
2727-17 tion by hand. Tighten planetary mounting
bolts.
Step 6:
Remove the auger/conveyor planetary drive.
a. Sling the housing and attach to hoist. Take up
slack.
b. Remove four planetary mounting bolts.
c. Pull planetary drive (7) out of the chain case.
BK-194A
2727-20
C-46
NOTE Step 2:
Do not tighten bolts until the chain is Lower the deck panel.
tensioned.
Step 3:
NOTE Start machine and run conveyor to check for
Grease chain if chain case was cleaned (use proper operation.
three tubes of grease).
Step 4:
EQUIPMENT PREPARATION
Step 1:
Check fluid in the conveyor planetary drive (1 and
NOTE
Check fluid level with augers lowered.
3416-16
C-47
AUGER/CONVEYOR DRIVE CHAIN AND SPROCKETS


Disassembly Assembly ✓ Adjustments

• Augers lowered.
• Screed removed.
C-48
AUGER/CONVEYOR DRIVE IMPORTANT

To operate conveyors while the screed is dis-
CHAIN AND SPROCKETS connected, jumper wires must be connected
between terminals E and F at both the L.H.
and R.H. rear screed receptacles.
REMOVAL
Step 1:
Remove rear cover (1) on the drive chain case.
a. Remove three bolts on each side of the cover.
b. Remove cover and set aside.
E
F
1 2783-23
a. On the control console, turn the main power

ON.
b. Switch the auger control (L.H. or R.H.) to
MANUAL.
c. Stop the auger/conveyor drive chain when the
2727-10 master link (the link with the cotter pins) is
Step 2: located in the center of the opening.
If breaking the chain, jog the motor to move the d. Turn off the machine. Disconnect battery.
chain until the master link (2) is in the center of
the chain case opening. Step 3:
Remove top cover (3) on the chain case.
a. Remove four bolts securing the cover.
b. Remove the hydraulic hose clamps.
c. Remove the cover.
3
2
2727-16
NOTE
One person should operate the auger/con-
veyor drive while a second person watches
2727-14
for the master link as the chain is run through
the chain case.
C-49
Step 4: e. Drive the link pins out to break the chain.

OPTIONAL: Break the auger/conveyor drive f. Reinsert one mounting bolt into the chain case
chains. and tie off the top part of the drive chain.
g. Tie off the bottom part of the drive chain.
NOTE
Chains do not have to be broken to remove Step 5:
conveyor sprockets. Remove auger shaft from the bottom rear
sprocket.
a. Loosen the planetary mounting bolts (4). Do a. Loosen four planetary mounting bolts (4).
not completely remove them at this time. Do not completely remove them at this time.
b. Loosen the chain tensioner bolt (5). b. Loosen the drive chain tensioner bolt (5).
c. Remove the master link cotter pins. c. Disconnect or remove the outer bearing
supports (6).
4 4
5 6
2727-17
2727-2
d. Loop mechanics wire through the drive chain
above and below the master link. This will help d. Remove the inner kick back augers to gain
keep the chain from falling to the bottom of the access to the inner auger bearing set screws
chain case. (7).
2727-21
2727-16
C-50
e. Remove bearing flange mounting bolts (8). Step 7:

f. Loosen the set screws in the flange bearing Clean the chain case interior if desired.
(9) on the side of the chain case at the shaft.
g. Attach a lifting device to the auger shaft
assembly and pull shaft from the drive sprock- INSPECTION
et. Drive sprocket (10) stays in the chain case.
h. Lift auger drive sprocket out of the chain case Inspect the auger/conveyor drive chain. Make sure
if necessary. Replace the sprocket and auger links and pins are not damaged. Replace chain if
shaft if necessary. necessary.
Inspect the auger/conveyor sprockets and planetary

shaft. (Shaft may be mushroomed on the end.)
10 Replace components if worn or damaged.
Inspect all bearings for wear or damage. Replace if

necessary.
9 8
INSTALLATION
Install the auger/conveyor chain case and sprockets
by reversing the removal procedures.
NOTE
Be careful to align auger shaft through the
2727-23
flange bearings and auger drive sprocket
splines.
Step 6:
Remove the top sprocket. NOTE
a. Attach a lifting device around the auger/con- Apply surface sealant to the planetary drive
veyor motor/planetary drive and take up slack. mounting surface. Apply thread sealant to
b. Pull the chain up off of the top sprocket and drive mounting bolts. Do not tighten the bolts
support it with mechanics wire. completely until the chain is tensioned.
NOTE NOTE
Reinsert one mounting bolt into the chain Turn chain tension adjusting screw until chain
case and wrap the mechanics wire around has approximately 1/4" (6mm) of total deflec-
the bolt. This will help keep the chain from tion by hand. Tighten planetary mounting
falling to the bottom of the chain case. bolts.
c. Remove the mounting bolts and lift the
motor/planetary drive away from the chain
case. Drive sprocket (11) should come out on
the shaft.
11
BK-194A
2739-3
C-51
WARNING
Do not adjust the drive chains when the
engine is operation. Injury could result if the
chain moves. 1
NOTE
Grease the chain (use 3 tubes of grease) if
the chain case was cleaned. 2
EQUIPMENT PREPARATION
Step 1:
Check fluid in the conveyor planetary drive (1 and
3416-16
NOTE
Check fluid level with augers lowered. Step 2:
Start machine and run conveyor to check for
proper operation.
Step 3:
C-52
CONVEYOR DRIVE SHAFT AND SPROCKETS


Disassembly ✓ Assembly ✓ Adjustments

• Augers raised.
• Screed removed.
C-53
CONVEYOR DRIVE SHAFT a. On the control console, turn the main power
ON.
AND SPROCKETS b. Switch the auger control (L.H. or R.H.) to
MANUAL.
c. Stop the conveyor when the master link (the
REMOVAL link with the cotter pins) is located in the
center of the opening.
Step 1: d. Turn off the machine. Disconnect battery.
Remove the auger/conveyor drive chain case
covers. Step 3:
a. Remove the four bolts that secure the top OPTIONAL: Remove the auger/conveyor drive
cover (1). assembly. (See “Auger/Conveyor Drive Assembly,
b. Remove the hydraulic hose clamps from the pages C-37 to C-43 for procedures.)
top cover (2).
c. Remove three bolts (3) from either side of the Step 4:
front cover. OPTIONAL: Break the auger/conveyor drive chain.
d. Remove both covers.
NOTE
Chain does not have to be broken.
a. Loosen four planetary mounting bolts (4). Do

2 not completely remove them at this time.
1 b. Loosen the chain tensioner bolt (5).
2727-10
Step 2:
If breaking the auger/conveyor drive chain, jog 5
the conveyor to move the chain to find the master
link. Position master link in the center of the
chain case opening.
2727-10
IMPORTANT
To operate conveyors while the screed is dis- c. Remove the master link cotter pins.
connected, jumper wires must be connected d. Loop mechanics wire through the drive chain
between terminals E and F at both the L.H. above and below the master link. This will help
and R.H. rear screed receptacles. keep the chain from falling to the bottom of the
chain case.
E
F
2783-23
C-54
e. Drive the link pins out to break the chain. e. Loosen set screws securing the outer convey-
f. Reinsert one mounting bolt into the chain case or chain sprocket (10).
and tie off the top part of the drive chain. f. Remove mounting bolts that secure the outer
g. Tie off the bottom part of the drive chain. conveyor bearing.
g. Loosen set screws on the outer conveyor
bearing.
h. Remove the outer conveyor bearing.
10
2727-16
Step 5:
Remove conveyor shaft from the auger/conveyor 2727-31
feeder drive. i. Pull the conveyor shaft and bearing (11) out of
a. Loosen auger/conveyor planetary mounting the chain case. The inner drive sprocket
bolts and chain tensioner bolt. Do not remove remains in the chain case.
bolts at this time. J. Remove the drive sprocket through the open-
b. Attach a lifting device to the conveyor shaft. ing in the front of the chain case.
Take up slack.
c. Loosen set screws (6) securing the inner
conveyor chain sprocket (7) and slide sprocket
onto shaft (8) to gain access to the inner con-
veyor bearing. 11
d. Remove mounting bolts (9) that secure the
inner conveyor shaft bearing.
6
7
move sprocket in
2727-31
8
9
2727-27
C-55
Step 6: ASSEMBLY/INSTALLATION
Remove the top sprocket (12).
a. Attach a lifting device around the auger/con- Install the conveyor drive shaft and sprockets by
veyor motor/planetary drive and take up slack. reversing the disassembly and removal procedures.
b. Pull the drive chain up off the top sprocket and
tie it off with mechanic’s wire. NOTE
Be careful to align conveyor shaft through the
flange bearings and conveyor drive sprocket
splines.
NOTE
Apply thread sealant to bearing screws when
12 installing through the side of the chain case
at the shaft.
NOTE
Apply surface sealant to the planetary/drive
mounting bolts. Do not tighten the bolts com-
pletely until the chain is tensioned.
NOTE
Grease the chain (use 3 tubes of grease) if
2727-20 the chain case was cleaned.
NOTE
Reinsert one mounting bolt into the chain
case and wrap the mechanic’s wire around ADJUSTMENT
the bolt to keep the chain from falling to the
bottom of the chain case. NOTE
If completing installation, proceed to Step 3. If
c. Remove planetary mounting bolts and lift the just performing adjustment, follow entire
motor/planetary drive away from the chain adjustment procedure.
case. Sprocket will come out on the shaft.
Step 1:
Step 7: Remove chain case cover by removing three bolts
Clean the chain case interior if desired. on either side of cover.
WARNING
Do not adjust the drive chains when the
INSPECTION engine is operating. Injury could result if the
chain moves.
Inspect inner and outer sprockets for wear or
damage. Replace if necessary.
Step 2:
Loosen four planetary mounting bolts on both
Inspect conveyor shaft for damage. Replace if
sides of the cover.
necessary.
Inspect shaft keys for wear. Replace if necessary.
Inspect inner and outer bearings for wear or damage.

Replace worn or damaged bearings.
C-56
Step 3: EQUIPMENT PREPARATION

Turn the chain tensioner adjusting screw (12) until
the conveyor drive chain has 1/4" (6mm) deflec- Step 1:
tion by hand (as shown in illustration). Connect battery.
IMPORTANT
To operate conveyors while the screed is dis-
connected, jumper wires must be connected
between terminals E and F at both the L.H.
and R.H. rear screed receptacles.
E
F
2783-23
BK-194A Step 2:
Run the conveyor to check for proper operation.
Step 4: Step 3:
Tighten the planetary mounting bolts (13). Attach screed.
13
2727-14
Step 5:
Install the chain case covers.
C-57
AUGERS, SHAFTS AND BEARINGS


✓ Disassembly Assembly Adjustments

• Screed removed. ✓ None ✓ None
• Augers raised.
switch turned OFF.
C-58
AUGERS, SHAFTS AND Step 4:

Remove the auger shaft from the bottom drive
BEARINGS sprocket.
a. Loosen four planetary mounting bolts. Do not
completely remove the bolts.
REMOVAL b. Loosen the drive chain tensioner bolt (4).
c. Loosen set screws in the inner auger flange
Step 1: bearing (5) on the side of the chain case at
Remove all auger segments (1). the shaft.
CAUTION
Remove one segment at a time. Be careful
not to drop the auger segments as they are 4
cast Ni-Hard and very brittle.
NOTE
Mark each auger segment as it is removed
and reinstall each segment in its correct 5
position.
a. Loosen mounting bolts and nuts.

b. Support the auger sements with hardwood
blocking and remove screws.
c. Remove the auger segments (each auger
segment comes apart in two pieces).
2727-21
d. Remove mounting bolts (6) from the inner

1 auger bearing.
3 2
2727-2
Step 2:
Stabilize the auger shaft (2) with a sling or other
adequate support.
2727-23
Step 3: e. Attach a lifting device to the auger shaft

Remove the outer bearing hanger (3) and bearing. assembly and pull shaft from the drive sprock-
a. Remove the allen bolts from the bottom of the et. Drive sprocket remains in the chain case.
shaft.
b. Remove four large mounting bolts at the top of
the hanger. DISASSEMBLY
c. Use a soft hammer if necessary to remove the
hanger bearing from the shaft. Step 1:
Remove the outer auger bearings from supports.
NOTE
Remove any asphalt or rust from the shaft so Step 2:
the hanger bearing will slide more easily off Inspect and replace all worn or damaged
the shaft. components.
C-59
INSPECTION EQUIPMENT PREPARATION

Inspect auger shaft and splines for wear or damage. Step 1:
Replace if necessary. Connect battery or turn battery master disconnect
switch ON.
Inspect inner and outer bearings for wear or damage.
Replace worn or damaged bearings, or repack old Step 2:
bearings with new seals. Lubricate auger bearings, if required.
Inspect auger sections for wear or damage. Replace Step 3:

if necessary. Test augers for proper operation.
IMPORTANT
ASSEMBLY/INSTALLATION To operate conveyors while the screed is dis-
connected, jumper wires must be connected
Install augers, shafts and bearings by reversing the between terminals E and F at both the L.H.
removal procedures. and R.H. rear screed receptacles.
CAUTION
Replace one segment at a time. Be careful
not to drop or over-tighten the auger seg-
ments; they are cast Ni-Hard and very brittle.
Torque to 55-60 lb-ft (68 to 81 N•m). E
IMPORTANT F
When reassembling the auger shaft assem-
bly, make sure the bearing hanger is bot-
tomed out and level at the shoulder and that
the shaft is perpendicular to the hanger bar.
This will prevent the auger shaft from wearing
out the center bearing.
2783-23
Step 4:
Attach screed.
C-60
AUGER AND TUNNEL GUARD EXTENSIONS



• Augers lowered.
switch turned OFF.
Note: Refer to Operator’s Manual for different extended width paving considerations.
C-61
AUGER AND TUNNEL GUARD Step 3:

Pull tunnel guard extension (4) off.
EXTENSIONS
REMOVAL 4
Step 1:
Remove lock pin.
a. Remove cotter pin (1).
b. Pull lock pin (2) out.
2728-8
1
DISASSEMBLY
Step 1:
Remove auger guards if present.
a. Remove bolts securing guards (5) above the
augers.
3416-21 b. Remove bolts securing guards (6) on the
tunnel extension.
Step 2:
Loosen set screws (3) on top of tunnel.
35
3 64
BK-180
3416-21
Step 2:
Remove augers and shafts. (See “Augers, Shafts
and Bearings” on pages C-58 to C-60.)
ASSEMBLY/INSTALLATION
Assemble and install the auger and tunnel guard
extensions by reversing the disassembly and removal
procedures.
C-62
OPTIONAL POWER FLIGHT AUGERS



• Augers retracted.
• Augers raised.
switch turned OFF.
• Screed removed.
C-63
OPTIONAL POWER FLIGHT Step 3:

Disassemble inner auger bearing assembly while
AUGERS still on auger shaft.
a. Remove lube line to center bearing.
b. Remove bearing shield bolts (6).
REMOVAL c. Pull bearing shield (7) away from bearing.
d. Pull inner auger bearing (8) away from chain
Step 1:
case and sprocket (9).
Remove auger extension cylinder.
e. Remove O-ring (11).
a. Remove hydraulic hoses to the cylinder.
f. Pull out, split apart and remove collar (10).
b. Mark, cap and plug all fittings and hoses.
c. Remove cylinder pivot pins (1).
d. Remove cylinder (2).
8 10
7
1
6
9
2 11
1 BK-64
Step 4:
Release auger drive chain tension.
BK-62A
Step 5:
Step 2:
OPTIONAL: Break auger drive chain. (See
Remove outer auger bearing and support.
“Auger/Conveyor Drive Chain and Sprockets” on
a. Block auger assembly for support.
pages C-48 to C-52 for procedures.)
b. Remove bearing support mounting bolts (3).
c. Remove cylinder bracket.
Step 6:
d. Remove outer bearing mounting bolt and
Remove power flight auger assembly.
washer (4) from auger base.
a. Attach lifting device to auger assembly.
e. Remove outer bearing and support (5).
b. Pull auger base out of the chain case and
sprocket.
BK-65
4
BK-63
C-64
DISASSEMBLY ASSEMBLY
Step 1: Step 1:
Remove cap screws and nuts and remove auger Connect auger base sections by sliding outer
segments. telescoping section onto the inner stationary
section.
CAUTION
Remove one segment at a time. Be careful
not to drop auger segments; they are cast SLIDE SECTION
Ni-Hard and very brittle.
BASE SECTION BK-67A
Step 2:
BK-66 Install augers and tighten cap screws and nuts.
CAUTION
Step 2: Install one segment at a time. Be careful not
Separate auger base sections by sliding outer to drop auger segments; they are cast Ni-
telescoping section away from the inner station- Hard and very brittle. Torque segments to 50-
ary section. 60 lb-ft (68-81 N•M).
SLIDE SECTION
BK-66
BASE SECTION BK-67A
C-65
INSTALLATION Step 2:
Install outer auger bearing and support.
Step 1: a. Install outer bearing and support (5) onto outer
Install power flight auger assembly. auger shaft.
a. Place inner auger bearing (8) on base shaft. b. Install outer bearing mounting bolt and washer
b. Install split collar (10) around stationary shaft (4) to the auger base, through the bearing and
groove and secure with O-ring (11). into the end of the slide section.
c. Install cylinder bracket (3).
d. Install the bearing support mounting bolts (3a).
8 10
7 3
9
11
5
BK-64
c. Attach lifting device to auger assembly.

d. Install auger base into chain case and
sprocket.
e. Install four bolts through the bearing shield
4
and flange bearing into chain case. BK-63
Step 3:
Install the auger extension cylinder.
a. Install cylinder (2) onto shaft.
b. Install cylinder pivot pins (1) at both ends of
cylinder.
c. Connect hydraulic hoses to the cylinder.
BK-65
1
3
BK-62A
C-66
EQUIPMENT PREPARATION Step 3:

Check fluid level in hydraulic tank. Fill if needed.
Step 1:
Connect battery or turn battery master disconnect Step 4:
switch ON. Attach screed.
Step 2:
Test power flight augers.
a. Start engine.
b. Extend and retract power flight augers to
check for proper operation.
c. Check extension/retraction speed in relation to
synchronis movement with screed extensions.
Adjust flow control valve as needed to coordi-
nate movement. (See “Hydraulics” section for
details.)
C-67
OPTIONAL MIXER/AGITATOR


• Hopper wings lowered.
switch turned OFF.
C-68
OPTIONAL MIXER/AGITATOR Step 2:

Remove bearings.
a. Loosen four motor mounting bolts (5) and the
chain tensioner screw (6).
REMOVAL b. Remove chain case cover mounting bolts (7).
c. Back off bearing set screws. Unbolt bearings
Step 1:
(8) from housing.
Disconnect hydraulic hoses.
d. Remove set screw on sprocket.
a. Loosen fittings.
e. Remove shaft (9).
b. Mark, cap and plug all fittings and hoses.
f. Remove sprocket (10) through case opening.
Step 2:
Remove mixer/agitator assembly.
a. Attach lifting device to mixer/agitator lifting eye
(1). Take up slack.
b. Remove four mounting bolts (2).
c. Lift mixer/agitator out of the hopper. 5
10 6
1 9 4
7
3 8
BK-84A
Step 3:
2 Remove mixer/agitator motor.
a. Relax the chain tensioner screw (6).
b. Remove mounting bolts (5).
c. Lift the chain up and support it.
d. Remove the motor.
BK-83A
DISASSEMBLY
Step 1:
Remove mixer/agitator paddle segments.
a. Support paddle segments (3) and remove
screws (4).
b. Inspect segments and replace if worn or
broken.
5
1144-098A
4
4
3
1144-043
C-69
ASSEMBLY/INSTALLATION EQUIPMENT PREPARATION

Assemble and install the mixer/agitator by reversing Step 1:
the disassembly and removal procedures. Connect battery or turn battery master disconnect
switch ON.
NOTE
Paddles must be assembled as previously Step 2:
installed to obtain proper directional agitation. Test mixer/agitator.
a. Start engine.
NOTE b. Run the mixer/agitator to check for proper
Add hydraulic fluid to the mixer/agitator operation.
motor, connect hydraulic hoses as previously
connected and tighten fittings. Reverse hoses
to reverse rotation.
IMPORTANT
Adjust the chain tensioner screw (6) so there
is approximately 1/2" (13mm) total of free
rotational movement in the mixer/agitator
paddles. Tighten the motor mounting bolts
(5).
NOTE
Add grease to the mixer/agitator chain and
install the cover.
C-70
OPTIONAL MATERIAL LEVEL INDICATOR



• Battery disconnected or battery master disconnect ✓ None ✓ None
switch turned OFF.
C-71
OPTIONAL MATERIAL LEVEL Step 3:

Remove the sensor assembly from the bottom of
INDICATOR the flow gate.
REMOVAL INSPECTION
Step 1: Check the mercury switch for ON/OFF condition with
Tag terminals and disconnect wires from the a volt meter. Replace the mercury switch or the
sensors to the indicator box. complete sensor assembly as required.
Step 2:
Remove the material indicator assembly if
necessary by removing one mounting bolt from
INSTALLATION
the mounting bracket (1). Install the optional material level indicator by revers-
ing the removal procedures.
2783-16
C-72
APPENDIX C-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.
Auger/Conveyor Planetaries 00108-074-00 Auburn Gear Model 6 Double Reduction Wheel Drive Service Manual (MH422-893)
Power Flow Gate Cylinders 00112-569-00 Cross Cylinder (2-1/2" bore x 12" stroke) Service Instructions
Optional Truck Hitch Cylinder 00112-365-00 Cross Cylinder (#NW0150-05800-0100-028305) Service Instructions
Optional Telescoping PowerFlight 00112-472-00 Cross Cylinder (2-1/2" bore x 36" stroke) Service Instructions
Auger and Tunnel Cylinders
C-1-1

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Table of Contents ............................................................................................................C-1

Appendix C-1 Vendor Component Publications Listing ...............................................C-1-1

SAFETY PRECAUTIONS CAUTION

entire length of the screed. Ground clearance of the

The optional hydraulically extendible Powerflight

Mounting of the material feed sensors on the ends of

A second choice for mounting of feed sensors is on

FEED SENSOR, EDGER PLATE

MATERIAL HANDLING SYSTEM

Systematic inspection may reveal damage that, if not

• Keep it clean: Dirt, grease, oil and debris only get

• Bolts, nuts and screws: Check that they are not

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

• Electric wires and connectors: Look for cracked

• Hose and fluid lines: Look for wear, damage and

MATERIAL HANDLING SYSTEM TROUBLESHOOTING

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

• Use all senses to observe and locate troubles.

3.Open electrical 3. Check voltage and continuity of manual override

4. Loose 4. Check L.H. and R.H. console wiring harness

5. Circuit breaker 5. Check continuity of “console” circuit breaker in

MATERIAL HANDLING SYSTEM TROUBLESHOOTING (CONTINUED)

AUGER/CONVEYOR WILL NOT OPERATE – ALL MACHINES

PROBLEM CAUSE(S) REMEDY(S)

L.H. & R.H. 6. Loose 6. Check screed electrical connections to tractor on

8. Potentiometer 8. Check auger speed potentiometer in screed con-

9. Force motor 9. Check voltage, resistance and “null” at force

12. Auger pump(s) 12. Check auger/conveyor pump(s) operating system

15. Charge 15. Check charge pressure from traction pump(s).

MATERIAL HANDLING SYSTEM TROUBLESHOOTING (CONTINUED)

AUGER/CONVEYOR WILL NOT OPERATE – ALL MACHINES

PROBLEM CAUSE(S) REMEDY(S)

18. Auger/ 18. Check auger/conveyor motor(s) for function and

19. Auger/ 19. Check auger/conveyor planetary for function.

20. Mechanical 20. Check function of feeder drive system. Retension

MATERIAL HANDLING SYSTEM TROUBLESHOOTING (CONTINUED)

AUGER/CONVEYOR WILL NOT OPERATE IN AUTO, BUT WILL OPERATE IN MANUAL

PROBLEM CAUSE(S) REMEDY(S)

2. Motion/brake 2. Check motion/brake circuit breaker within

3. Motion relay 3. Check function of motion relay within electrical

4. Open or 4. Check continuity and voltage of circuit. Isolate

5. Motion limit 5. Check function of motion limit switch in L.H.

MATERIAL HANDLING SYSTEM TROUBLESHOOTING (CONTINUED)

SYSTEM(S) RUN SLOW OR ERRATICALLY

PROBLEM CAUSE(S) REMEDY(S)

3. Main hydraulic 3. Check main hydraulic filter(s) for clogging and

4. Strainers in 4. Check strainer(s) within hydraulic tank for clog-

5. Charge 5. Check traction pump(s) for proper charge pres-

6. Charge 6. Check charge pressure filter between traction

7. Pilot control 7. Check auger/conveyor pump(s) pilot control fil-

8. Pumps 8. Check all pumps for cavitation (air intrusion within

MATERIAL HANDLING SYSTEM TROUBLESHOOTING (CONTINUED)

SYSTEM(S) RUN WITHOUT MATERIAL, BUT STALL UNDER LOAD

PROBLEM CAUSE(S) REMEDY(S)

2. Pump(s) 2. Check auger/conveyor pump(s) compensator

3. Bearing(s) 3. Check for failed auger or conveyor bearings.

4. Mechanical 4. Check for mechanical binding or restriction within

5. Auger/convey- 5. Check function of auger/conveyor planetaries.

6. Mechanical 6. Check for mechanical failure in (broken drive

HOPPER SIDES/WINGS (HINGE REBUILD)

✓ Removal Inspection/Specification ✓ Installation

Machine Set-up Special Tools Fabricated Tools