OPERATION AND MAINTENANCE MANUAL Ingersoll

Transcription

OPERATION AND MAINTENANCE MANUAL
Ingersoll-Rand Blaw Knox
PF-161 Paver/Finisher
CPN 13858741
March 6, 2006
Read and understand this manual before operating or servicing this equipment.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
TABLE OF CONTENTS
TITLE
SECTION
INTRODUCTION
PROCEDURE WHEN RECEIVING THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IDENTIFICATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MACHINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MACHINE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRACTION DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRACTION LOCK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PIVOT STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATOR’S UMBRELLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TRUCK HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
POWER FLOW GATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DUAL FEED SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CONVEYORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AUGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AUTOMATIC FEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MAT KONTROL® II WITH PADDLE SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MAT KONTROL® II WITH ULTRA 3S® SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SMOKE-EATER® VENTILATION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WASHDOWN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SCREED CHOICES/SCREED OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SCREED HEATERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIESEL ONLY HEATERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIESEL HEATERS WITH AUTOMATIC TEMPERATURE AND IGNITION CONTROL (ATIC) . . . . 13
PROPANE (LPG) HEATERS WITH ATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WEDGE-LOCK® SCREED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WEDGE-LOCK® SCREED EXTENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5/5B HYDRAULIC SCREED EXTENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
POWER SLOPE OPTION FOR 2.5/5B HYDRAULIC EXTENSIONS. . . . . . . . . . . . . . . . . . . . . . . . 14
BERM ATTACHMENT OPTION FOR 2.5/5B HYDRAULIC EXTENSIONS . . . . . . . . . . . . . . . . . . . 15
OMNISCREED® IA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL EQUIPMENT OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front Wheel Power Assist Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Material Indicator Kit Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Blaw-Kontroll® II Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
UltraEye® V Grade Sensor Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Automatic Level Control (Also Known as a Joint Matcher) Option . . . . . . . . . . . . . . . . . . . . . . . 17
Floating Beam Reference Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mat Reference Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Additional Operator’s Umbrella Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
IDENTIFICATION OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1
TABLE OF CONTENTS
TITLE
SECTION
SAFETY
BE AWARE OF SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
UNDERSTAND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SELECTION AND QUALIFICATION OF PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
ORGANIZATIONAL MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
MANDATORY SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
LOADING AND UNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Loading Dock with Ramp (Preferred Method) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Alternate Ramp Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
PRE-START INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
SAFETY INSTRUCTIONS GOVERNING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
WARNING OF SPECIAL DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
ASSEMBLY
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
GENERAL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Before you Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Selecting a Site for Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Unloading the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Installation of the Steering Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Installation of the Edger-Plate Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Installation of the Automatic Feed Control Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Installation of the Paddle Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Installation of Ultra 3s Ultra Sonic Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Muffler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
OPTIONAL INSTALLATION GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Installation of the Cut-off Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Installation of Additional Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Installation of 1-foot Bolt-on Screed Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Installation of the 18-inch Tapered-Joint Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Installation of the 8-foot Wedge-lock Screed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Installation of Ultrasonic 4 Sonic Averaging System/Sonic Joint Matcher . . . . . . . . . . . . . . . . . 2-28
Installation of the Ags (7.5) Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
OPERATING CONTROLS AND INSTRUMENTS
2
DIRECTION-SPEED CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Steering Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
MAIN CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Engine Tachometer/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Wait to Start Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
TABLE OF CONTENTS
TITLE
SECTION
Water in Fuel Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Stop Engine Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Check Engine Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Brake Engaged Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Empty Tunnel Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Hydraulic Filter Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Water Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Battery Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Front Wheel Assist Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Starter Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Engine Kill Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Transmission Shift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Motor Shift Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
RH Flowgate Control Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
LH Flowgate Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Screed Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Auger Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Hopper Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
RH and LH Conveyor Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Screed Vibrator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Governor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Throttle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Positive Traction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Pivot Steer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Truck Hitch In/Out Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Ventilation Control Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Brake Release Hand Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Brake Release Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Material Indicator (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Flow Gate Position Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Rear Control Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Jog Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Up/Down Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-Position Function Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Slope/Grade Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Warning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Warning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Up/Down Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Screed Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
LH Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Extension Slope Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
LH and RH Flow Gate Control Toggle Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Auger Override Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Auger Extension Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Extension Heater Igniter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Extension Fuel Pump Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Main Fuel Pump Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Main Igniter Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3
TABLE OF CONTENTS
TITLE
SECTION
Auger Speed Control Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Screed Extension In/Out Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
RH Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Extension Fuel Pump Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Extension Heater Igniter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Auger Override Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Auger Extension Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Fuel Pump Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Extension Slope Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Screed Extension In/Out Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Auger Speed Control Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Main Igniter Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Main Fuel Pump Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
OPERATING INSTRUCTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Pre-Start Checks and Verifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Starting the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Suggestions to Make Cleanup Easier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Positioning the Machine and its Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Initial Screed Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Initial Screed Angle-of-Attack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Lighting the Screed Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Positioning the Material Truck and Starting to Pave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
OPERATING THE MACHINE - GENERAL GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
MOVING THE MACHINE - UNDER PROPULSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
MOVING THE MACHINE BETWEEN WORKSITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Securing the Machine to the Transporter (Tiedown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
MAINTENANCE INSTRUCTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
CLEAN UP AND WASHDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
LUBRICATION AND SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Daily Maintenance Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Weekly Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Monthly Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Quarterly Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Semi-Annual Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Annual Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Miscellaneous Maintenance Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Preventative Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Daily Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Front Conveyor Bearing - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Rear Conveyor Bearings - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Auger Bearings - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Screed Vibrator Shaft Bearings - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
4
TABLE OF CONTENTS
TITLE
SECTION
Hydraulic Fluid - Check Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Engine Oil - Check Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Engine Radiator - Check Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Cooling Fan - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Truck Hitch Option Rollers - Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Engine Air Intake Piping - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Drive Belts - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Fuel Water Separator - Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Crankcase Breather Tube - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Conveyor Chains - Inspect/Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Weekly Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Truck Hitch Option Slides - Clean/Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Screed Depth Cranks - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Screed Pivot Points - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Front Wheel King Pins - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Front Wheel Bogie Pivot Bearings - Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Monthly Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Parking Brake - Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
QUARTERLY MAINTENANCE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Engine Oil and Filter - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Air Cleaner - Check/Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Short-Coupled Drive Shaft - Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Fuel Pump - Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Radiator Hoses - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Auger/Conveyor Drive Chains - Check/Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Hopper Hinge Assembly - Inspection/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Auger Section - Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
SEMI-ANNUAL MAINTENANCE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Hydraulic Fluid and Filters - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Draining the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Changing Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Removal and Cleaning of Relief (In Hydraulic Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Changing Hydraulic System Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Refilling Hydraulic System with Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Engine Coolant - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
ANNUAL MAINTENANCE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
Front Bogie Wheels - Repack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Pump Drive Box - Change Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Auger/Conveyor Planetaries - Change Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Drive Wheel Planetaries - Change Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Engine Fuel Filter - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
Changing a Canister - Type Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
Changing a Spin-On-Type Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Washdown Fuel Filter - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
MISCELLANEOUS MAINTENANCE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Adjustment of Hopper Wiper Bars - As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Adjustment of Swing Console - As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Adjustment of Steering Consoles and Seats - As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
Adjustment of Hopper Side Extensions - As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
Drive Tire Servicing and Hydroinflation - As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5
TABLE OF CONTENTS
TITLE
SECTION
TROUBLESHOOTING
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
General Fault Isolation Tips/Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
How This Section Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
General Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Alarms Indications and Remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
BLAW KONTROL® ULTRASONIC GRADE CONTROL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 6-6
TECHNICAL SPECIFICATION
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Machine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Miscellaneous Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
FUEL AND LUBRICANT SPECIFICATIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
HYDRAULIC OIL REQUIREMENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
LUBRICATING OIL/GREASE (EXCEPT ENGINE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
ENGINE LUBRICATING OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
DIESEL FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
SCHEMATICS
SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
RECOMMENDED SERVICE PARTS
INDEX
WARRANTY INFORMATION
6
INTRODUCTION
1
INTRODUCTION
INTRODUCTION
The purpose of this manual is to provide the operator and site maintenance personnel with
knowledge of the fundamental rules and criteria to be followed for the on-site use and
maintenance of the Ingersoll-Rand Blaw-Knox PF-161 Paver/Finisher. This instruction manual
must be read and fully understood by the operator before operating the machine.
This manual consists of:
•
INTRODUCTION
•
Section 1, SAFETY
•
Section 2, ASSEMBLY
•
Section 3, OPERATING CONTROLS AND INSTRUMENTS
•
Section 4, OPERATING INSTRUCTIONS
•
Section 5, MAINTENANCE INSTRUCTIONS
•
Section 6, TROUBLESHOOTING
•
Section 7, TECHNICAL SPECIFICATION
•
Section 8, FUEL AND LUBRICANT SPECIFICATIONS
•
Section 9, SCHEMATICS
•
Section 10, RECOMMENDED SPARE PARTS
•
INDEX
Always keep this manual handy for quick reference. If any part of this manual cannot be
understood, contact your supervisor or local Ingersoll-Rand Blaw-Knox Distributor. This is an
essential condition for working safely with this machine. The correct machine operation, use,
and regular maintenance are also essential elements to provide the highest performance and
safety.
NOTE: This manual is accompanied by an engine instruction manual
provided by the engine’s manufacturer. Please follow the operation and
maintenance instructions as specified in both the machine and engine
manuals.
PROCEDURE WHEN RECEIVING THE MACHINE
Your machine has been tested, accurately checked, and prepared for shipment. Every part of
the machine, including the detached parts, has been accurately checked before being shipped
from the factory.
When you receive the machine, and before unpacking the equipment, check if damage has
occurred during transport and if any parts are missing.
Check the equipment by consulting the shipment documents.
If goods are damaged or if parts are missing, inform the freight agent as soon as possible.
They will inform you regarding how to proceed in order to make a complaint and get the
damaged or missing goods replaced.
2
INTRODUCTION
IDENTIFICATION DATA
An exact description of the model type and serial number of your machine will facilitate fast
and efficient response from our parts and service operations.
Always provide the model of your machine and its serial number when you contact the local
Ingersoll-Rand Blaw-Knox service or parts office.
We advise you to record your machine data in the following table to ensure that the paver/
finisher and engine information is readily available when you need it.
Table 1: Machine Identification Data
MACHINE IDENTIFIER
IDENTIFYING NUMBER
Paver/Finisher Model Number
Paver/Finisher Serial Number
Year of Manufacture
Engine Type
Engine Serial Number
MACHINE IDENTIFICATION
The Ingersoll-Rand Blaw-Knox PF-161 Paver/Finisher identification plate is located at
1, Figure 1 and the engine serial number can be found on its identification plate located at
2, Figure 1.
Figure 1
3
INTRODUCTION
GENERAL INFORMATION
All safety rules in Section 1 must be observed.
If further information is required concerning the recommended uses on PF-161 Paver/
Finisher, contact your local Ingersoll-Rand Blaw-Knox Distributor.
Ingersoll-Rand Company, Road Machinery Division
Shippensburg, Pennsylvania 17257 USA
Tel:
+1 - 717-532-9181 (Service and Warranty)
Fax:
+1 - 717-530-3402 (Service and Warranty)
Fax:
+1 - 717-530-3403 (Customer Service Parts)
Ingersoll-Rand reserves the right to make changes or modifications without prior notice and
without incurring any liability to retrofit machines previously shipped from the factory.
MACHINE DESCRIPTION
The Ingersoll-Rand Blaw-Knox PF-161 Paver/Finisher is a wheel-mounted, mid-sized paver/
finisher capable of placing bituminous base, binder and surface course mixes, cement or lime
stabilized sub-base and graded aggregate materials.
The PF-161 Paver/Finisher functionally consists of two sections (Figure 2). These sections are
called the tractor (1, Figure 2) and the screed (2, Figure 2). First, the tractor receives, delivers
and spreads the paving material in front of the screed. The tractor then, tows the screed
forward over the paving material.
As the screed is being towed over the paving material it levels, smooths, seals and starts the
compaction process on the mat (Newly paved area).
4
INTRODUCTION
The following paragraphs provide a brief description of each of the major components that
make up the PF-161 Paver/Finisher. Standard components are addressed initially followed by
brief descriptions of each of the available options.
Figure 2
ENGINE
The PF-161 Paver/Finisher is powered by the Cummins “Elite” series, EPA certified,
4 cylinder, turbocharged diesel model 4BTA 3.9...239 cubic inch (3.92) displacement, 107 hp
(80 kW) @ 2100 rpm. The engine is equipped with an oil cooler, replaceable oil filter,
replaceable fuel filter, replaceable air cleaner element and a real-time hour meter located in
the electrical junction box.
Refer to the Cummins Engine Operation and Maintenance Manual supplied with the Paver/
Finisher for additional engine operating and maintenance procedures.
ELECTRICAL SYSTEM
The PF-161 Paver/Finisher utilizes a 12-Volt, negative ground with a 105-Amp alternator for
its electrical needs. Wiring is color coded, number impregnated and the harness is wrapped in
polyethylene looms for maximum durability and ease of servicing. All circuits tie to circuit
boards located in the operator’s swing console and are equipped with automatic reset circuit
breakers.
5
INTRODUCTION
HYDRAULIC SYSTEM
The PF-161 Paver/Finisher is equipped with a hydraulic system that has a 151-liter (40 gal.)
reservoir capacity. Primary filtration is accomplished with 5.0 micron variable depth “Fiberglas”
filters on the inlet side of each traction-drive charge pump.
Secondary filtration is accomplished with 100-mesh strainers located on the suction side of the
general purpose and feeder drive-pump circuits. All hydraulic circuits are routed through a
central, easy access valve block equipped with interchangeable solenoid cartridge valves for
maximum reliability and easy servicing.
FUEL SYSTEM
The PF-161 Paver/Finisher is equipped with a 144-liter (38 gal.) fuel tank, equipped with a
replaceable filter. This fuel tank provides an onboard supply of diesel fuel for the engine,
heaters and the pressurized washdown system.
COOLING SYSTEM
The PF-161 is equipped with a 24.6 L (26 qt.) capacity cooling system.
BRAKES
The PF-161 Paver/Finisher primary braking is accomplished via the dynamics of a hydrostatic
traction drive system.
Hydraulic secondary parking brakes, an internal element of the planetary final drive units, can
be switch actuated from either operator’s console. These spring-applied secondary parking
brakes are automatically actuated when the main power switch is in the OFF position, electric
power is otherwise interrupted or there is a pressure drop in the general purpose hydraulic
system.
Refer to Section 5 of this manual for additional Brake information.
TRACTION DRIVE
The PF-161 Paver/Finisher is equipped with an independent, hydrostatic direct drive system
with electric/hydraulic controlled single-speed planetaries and 2-speed motors. Speed
selection is infinitely variable in each of the two speed ranges:
6
Low Range @ 2100 rpm.................................................
0 - 3.6 kph (2.2 mph)
High Range @ 2100 rpm................................................
0 - 15.9 kph (9.9 mph)
INTRODUCTION
TRACTION LOCK SYSTEM
The PF-161 Paver/Finisher is equipped with an electronically controlled hydraulic version of a
mechanical-locking differential. This provides a full-time tractive effort at both drive wheels with
an internal pressure modulation feature between right and left-side drives to compensate for
the unequal power requirement of turning.
PIVOT STEERING
An electrical switch on the operator’s console hydraulically destrokes the respective right or
leftside traction pump to the neutral position for power-assisted steering in confined quarters.
REAR SUSPENSION
Two 14:00 X 20 low-pressure (182 to 260 kPa (25 to 35 psi)), sand rib, high-flotation tires,
hydroinflated to 75%.
FRONT SUSPENSION
Four steerable, 305 mm (12 in.)-wide and 559 mm (22 in.)-diameter, solid-rubber tired wheels,
are mounted on a offset tandem bogie frame. Front machine weight is proportionally split
40-60% between the front and rear sets of bogies for optimum weight distribution. Tie-rod
synchronized steering cylinders (one on each side) are mounted on the outside of the bogie
frame for easy service access.
OPERATOR’S UMBRELLA
The PF-161 Paver/Finisher is equipped with an operator’s umbrella measuring 1373 mm
(54 in.) square. The umbrella comes with mounting hardware included.
TRUCK HITCH
Two bearing-equipped push rollers mounted on an oscillating frame with electric/hydraulic
actuated roller-equipped clamp arms quickly grip and secure a truck in proper attitude for
unloading material into the machines hopper. It automatically compensates for both minor
lateral and directional misalignment of the truck with the paver/finisher with no exposed
secondary slide mechanisms.
Table 2: Truck Hitch Specifications
CHARACTERISTIC
SPECIFICATION
Maximum Arm Opening
3302 mm (130 in.)
Minimum Arm Opening
1829 mm (72 in.)
Degree of Swivel
±8 °
Drift from Center
305 mm (12 in.) (Automatically self-centering)
7
INTRODUCTION
POWER FLOW GATES
Two separately operated, electrically controlled, adjustable flow gates (2, Figure 3) meter
material delivery to the augers. The gates are located in the conveyor tunnel entry at the rear
hopper.
DUAL FEED SYSTEMS
Separate, infinitely variable speed, hydrostatic planetary drive for right and left-side feed
systems provide optimum auger/conveyor operation throughout the machine’s entire
capability range. Right and left-side systems function independently and operation is
controlled either manually with electrical switches or automatically by electrical sensing
elements positioned at the outer end of each auger. Manual electrical switches are positioned
on the tractor operator’s swing console and on the screed control consoles. Maintenance-free
auger/conveyor bearings combine an exclusive patented seal with a new synthetic
hydrocarbon lubricant to eliminate the daily greasing requirement.
Figure 3
8
INTRODUCTION
CONVEYORS
Conveyor assemblies (1, Figure 3) consist of solid bars riveted to special, heat-treated steel,
offset link R2 (rapid -repair), heavy-bushed roller chain riding on forged steel sprockets.
Conveyor floor plates and rear wrap plates are constructed of abrasion-resistant QT steel with
a Brinell hardness range of 360 to 440 throughout the entire plate thickness.
Conveyor Tunnel Opening..............................................
1362 mm (53.625 in.)
Conveyor Floor Plate Thickness.....................................
10 mm (375 in.)
AUGERS
Augers (1, Figure 4) consists of replaceable, high alloy, cast steel hemi-screw sections.
Augers are adjustable in height hydraulically by simply actuating an electrical switch.
Table 3: Auger Specifications
CHARACTERISTIC
SPECIFICATION
Auger Diameter
356 mm (14 in.)
Auger Flight Thickness
16 mm (5/8-in.)
Auger Height Adjustment (above grade)
114-279 mm (4.5 - 10.5 in.)
Figure 4
9
INTRODUCTION
AUTOMATIC FEED CONTROL SYSTEM
The PF-161 Paver/Finisher is equipped with a Mat Kontrol® II to control the operating speed
of the dual feed systems. This system is supplied with a choice of either Paddle Sensors or
Ultra 3s® (Ultrasonic Sensing System) Sensors. The following paragraphs provide a brief
explanation of each sensor system.
MAT KONTROL® II WITH PADDLE SENSORS
An electric/hydraulic control arrangement that automatically controls both the on-off action and
infinitely variable operating speed of the dual feed systems.
Paddle Sensors are mounted at the outer end of each auger. From these locations, they
monitor the volume of material in front of the screed via actual contact with the material. As
these paddles detect the level of material present, they will actuate the feeder drives as
necessary and either cause an increase or decrease of conveyor speed or even start and stop
the conveyor(s), as appropriate, to maintain a consistent volume of material to the screed.
MAT KONTROL® II WITH ULTRA 3s® SENSORS
An electric/hydraulic control arrangement that automatically controls both the on-off action and
infinitely variable operating speed of the dual feed systems.
The Ultra 3s® sensors are positioned at the outer end of each auger. From these positions,
they monitor the volume of material in front of the screed and control the feeder drives, as
necessary, to maintain a consistent volume of material to the screed. Unlike the paddle system
described above, the Ultra 3s® system makes no actual physical contact with the material.
Instead, it works very similar to an active sonar system, as it sends sound pulses to the
material in front of the screed and waits for a bounce-back or echo. Accurate measurement of
the resulting time delay between output pulse and the returning echo results in a level of
accuracy rivaling mechanical means such as paddles. This system is much less vulnerable to
heat and abrasions than the paddle system since it has no physical contact with the material.
SMOKE-EATER® VENTILATION CONTROL SYSTEM
This is a machine-mounted heat and fume extraction system that provides a cleaner, cooler
and more environmentally friendly work area for the machine’s operator and screedman. The
system is provided standard on all machines manufactured for domestic use.
The system consists of a single, hydraulically-driven, high-volume fan and two collector hoods.
The system gathers heat and fumes from the paver’s auger and screed area and disperses
them into the atmosphere away from the operators via a single, deck-mounted exhaust stack.
The exhaust stack folds down to minimize transport height of the machine.
A 3-position switch controls the system. The three positions of this switch are; “ON” (constant
system operation), “AUTO” (system operates only when the paver is in motion), and “OFF”
(the system does not operate).
A vacuum sight switch is incorporated into the fan intake plenum to permit visual monitoring
of the system for proper operation.
10
INTRODUCTION
WASHDOWN SYSTEM
A pressurized diesel fuel washdown system with a 10.7 m (35 ft.) hose and spray valve nozzle
(2, Figure 5) is mounted on a self-storing, spring-retracting hose reel. Pressurization of the
washdown hose is controlled via a washdown hose pump switch (1, Figure 5).
Figure 5
CONTROLS
The dual control stations (right and left side) are each equipped with an operator’s seat
(2, Figure 6) and a direction/speed control pedestal (1, Figure 6).
A common, center-mounted, swing console (3, Figure 6) with position lock, provides both
control stations with electrical switch control of the main power, starter, throttle, horn, shifting
of traction-drive motors, right and left-side feed system function, screed lift, auger lift, folding
hopper, flow gates, screed vibrator function, parking brake, traction lock system, pivot
steering, optional truck hitch and optional front-wheel power assist. The screed vibrator
frequency/amplitude, feed system speed, flow gate override, powered screed functions and
mat depth are all controlled from the screed control boxes (4, Figure 6).
The swing console also contains the tachometer/hour meter and analog gauges for engine oil
pressure, water temperature, voltmeter and hydraulic oil temperature. Warning lights are also
included for “Brake On”, “Change Hydraulic Filter” and “Low Material” for units equipped with
optional material indicators.
11
INTRODUCTION
Refer to the Section 3, OPERATING CONTROLS AND INSTRUMENTS of this manual for a
complete description of the Operator’s Consoles, Controls and Instruments.
Figure 6
SCREED CHOICES/SCREED OPTIONS
The following paragraphs briefly describe the various screed choices and screed options that
may be on your machine.
SCREED HEATERS
All Blaw-Knox screeds offer screed heating options. Your machine will contain one of the
following screed heater systems.
DIESEL ONLY HEATERS
These heaters are unitized, diesel-fueled, SureFire® burner/blowers. Each unit contains a
manual switch-activated spark igniter. A built-in timer controls the fuel pump which supplies
diesel fuel to the screed heaters and the washdown system to provide an infinitely variable
15-30 minute run cycle time. Run cycle time is limited in this way to protect the pump from
accidental extended operational misuse which could result in premature pump failure.
12
INTRODUCTION
DIESEL HEATERS WITH AUTOMATIC TEMPERATURE AND
IGNITION CONTROL (ATIC)
These heaters are unitized, diesel-fueled, SureFire® burner/blowers. Each unit is equipped
with Automatic Temperature and Ignition Control (ATIC). This ATIC system automatically
ignites the heaters to preheat and maintain the temperature of the screed plate within 8° C
(14° F) range of any preselected temperature within the system’s operating range capability
of 80° to 177° C (175° to 350° F). The ATIC system incorporates flame failure and hightemperature shutdown safety features.
PROPANE (LPG) HEATERS WITH ATIC
These heaters are unitized, diesel-fueled, SureFire® burner/blowers. Each unit is equipped
with Automatic Temperature and Ignition Control (ATIC). This ATIC system automatically
ignites the heaters to preheat and maintain the temperature of the screed plate within 8° C
(14° F) range of any preselected temperature within the system’s operating range capability
of 50° to 160° C (125° to 320° F). The ATIC system incorporates flame failure and hightemperature shutdown safety features. This option includes a propane bottle mount, pressure
regulator valve and connector tubing. This option does not include the propane bottle itself.
WEDGE-LOCK® SCREED
The Wedge-Lock® Screed is a basic 2.44 m (8 ft.) fixed width, vibratory screed. The screed
contains a one-piece 623 mm (24.5 in.) wide x 13 mm (0.5 in.) thick, bolt-on replaceable,
abrasion-resistant, alloy-steel screed plate. The screed also comes equipped with springloaded MatStop® edger plates with replaceable wear shoes, edger guides and cut-off plates.
Bevel edger plates are optional.
A center crown kit is available with the Wedge-Lock® Screed. This mechanical, dual crown kit
provides simultaneous adjustment of center lead and tail crown from 76 mm (3 in.) positive to
19 mm (3/4 in) negative.
Below is a list of the Wedge-Lock® Screed specifications.
Table 4: Wedge-Lock® Screed Specifications
CHARACTERISTIC
SPECIFICATION
Standard Paving Range (with cut-off plates)
1.83 - 2.44 m (6 - 8 ft.)
Maximum Paving Width
5.79 m (19 ft.)
Paving Depth Range
6 - 203 mm (0.25 - 8 in.)
Optional to 305 mm (12 in.)
Vibrator Speed
0 - 3100 vpm (52 Hz)
13
INTRODUCTION
WEDGE-LOCK® SCREED EXTENSIONS
Wedge-Lock® screed extensions are used to increase paving width. These extensions to the
basic screed are available in 152 mm (6 in.), 305 mm (12 in.), 610 mm (24 in.) and 914 mm
(36 in.) lengths. They may be supplied either in kit form or individually.
Various options correspond to specific extension sizes. Table 5 below provides a list of these
extensions and the features available for each.
Table 5: Wedge-Lock® Screed Extensions Size and Options
Available Options
Size
Vibration
Heat
Center Crowning
Capable
152 mm (6 in.)
305 mm (12 in.)
xx
610 mm (24 in.)
914 mm (36 in.)
xx
xx
xx
2.5/5B HYDRAULIC SCREED EXTENSIONS
Optional, hydraulic telescoping extensions with replaceable screed plates mount on either a
basic or extended Wedge-Lock® Screed to permit increased paving width of up to 762 mm
(2.5 ft.) on either or both sides of the screed, while continuing to pave.
Slope control on each extension is accomplished manually up to a maximum 25 mm (1 in) in
305 mm (12 in.) positive in any extended width up to 25 mm (1 in.) in 305 mm (12 in.) negative
fully extended. An additional 305 mm (12 in.) modular extension can be installed on the outer
end of either or both 2.5/5B extensions to increase paving width up to a maximum of 4.57 m
(15 ft.).
POWER SLOPE OPTION FOR 2.5/5B HYDRAULIC EXTENSIONS
This is an electrically actuated power sloping arrangement with visual sight gauges which
replaces the standard mechanical sloping mechanism. This option provides for effortless
on-the-go slope control of each extension relative to the main screed up to 25 mm (1 in.) in
305 mm (12 in.) positive at any extended width and up to 25 mm (1 in.) in 305 mm (12 in.)
negative fully-extended. Slope control switches are located on the screed control consoles.
14
INTRODUCTION
BERM ATTACHMENT OPTION FOR 2.5/5B HYDRAULIC
EXTENSIONS
This option replaces the standard screed plate arrangement to provide up to 102 mm (4 in.) of
vertical rise in 610 mm (24 in.) at the outer edge of each extension. The addition of this option
provides the means to form water drainage channels up to 610 mm (24 in.) in from the edge
of the mat, reducing the need for curbing.
OMNISCREED® IA
This is a basic 2.44 m (8 ft.) power extendible, vibratory screed providing infinitely variable onthe-go-paving width flexibility with uniform compaction and surface texture across the entire
mat width. The main screed and both independent, front-mounted, hydraulically extendible
sections are equipped with vibrators and bolt-on replaceable, abrasion resistant QT Steel
screed plates. These plates are 457 mm (18 in.) wide on the main screed and 356 mm (14 in.)
wide on the extendible sections. All plates are 13 mm (0.5 in.) thick. Spring-loaded MatStop®
edger plates with replaceable wear shoes, edger guides and cut-off plates are included. Bevel
edger plates are optional. Below are the specification details for the OmniScreed® IA.
Table 6: OMNISCREED® Specifications
CHARACTERISTIC
SPECIFICATION
REMARKS
Standard Paving Width
1.83 - 4.0 m (6 - 13.5 ft.)
With cut-off plates
5.23 m (17 ft., 2 in.)
With optional Wedge-Lock®
extensions
Paving Depth Range
6 - 203 mm (0.25 - 8.00 in.)
Optional to 305 mm (12 in.)
Vibrator Speed
0 - 2500 vpm (42 Hz)
Center Crown
76 mm (3 in.) positive - 19
mm (0.75 in.) negative
Choice of either mechanical
or hydraulic-powered dual
crown kits to simultaneously
adjust center lead and tail
crown.
Extension Power Slope
Range
25 mm (1 in.) in 305 mm
(12 in.) positive
For any extended width
(0 to 8%)
2 main burners and 1 on
each extendible section
Diesel or propane-fueled
SureFire® burner blowers.
Each unit contains an
individual switch-activated
ingniter and provides fast
even heat over the entire
screed base regardless of
the extendible section
position.
Heat
15
INTRODUCTION
GENERAL EQUIPMENT OPTIONS
The following paragraphs provide brief explanation of the general options that are available
and may be present on your PF-161 Paver/Finisher. These options do not fall under any
particular category as did the screed options discussed earlier.
Front Wheel Power Assist Option
This is a separate, constant torque, hydrostatic-drive arrangement for the rear set of front
bogie wheels. It provides up to 20% more tractive effort in the machine’s paving speed range.
Material Indicator Kit Option
This kit consists of electrical sensing elements that when mounted on the flow gates audibly
warn the paver/finisher operator when material level drops below a preset level at the
conveyor tunnel entry.
Blaw-Kontroll® II Option
This option is an extremely accurate, electronic grade-and-slope control system. It
automatically maintains the elevation and transverse (side-to-side) slope of a paver/finisher’s
screed to preset specification parameters, with respect to a single reference. This is
accomplished by controlling the machine’s hydraulic system.
The system can also be set up to control the elevation of each side of the screed with respect
to grade by referencing from both sides of the paver/finisher simultaneously. The system will
sense and correct for deviation in grade elevation as small as 0.127 mm (0.005 in.) when using
the standard Blaw-Knox mechanical-grade sensor. Slope resolution is 0.005%.
16
INTRODUCTION
UltraEye® V Grade Sensor Option
This option is an ultrasonic “non-contacting” grade sensor for the Blaw-Kontrol® II system. This
option is directly interchangeable with the standard mechanical-grade sensor. This sensor
provides a resolution of 0.508 mm (0.020 in.).
Automatic Level Control (Also Known as a Joint Matcher) Option
This is an electric/hydraulic control system that automatically controls the elevation of the mat
being placed on one side of the paver/finisher with respect to a reference surface such as an
adjacent mat or curb. This option is also available in sets (2 each) to control mat elevation on
both sides of the machine simultaneously. The resolution of this system is 3.175 mm (0.1259
in.).
Floating Beam Reference Option
This option is used as a sensing reference for a Blaw-Kontrol® II Control System. It accurately
averages longitudinal irregularities in the grade over which paving is being performed. This
eliminates the expense of installing and maintaining stringline references. It is available in
6.10 m (20 ft.), 9.14 m (30 ft.) and 12.20 m (40 ft.) lengths and in sets (2 each) for dual grade
referencing.
Mat Reference Option
This is a 6.10 m (20 ft.) rear-mounted aluminum beam riding on eight (8) sets of spring-loaded
dual road wheels with the aluminum bridge and hardware required to match it to a 9.14 m
(30 ft.) front-mounted floating beam. This produces a 16.77 m (55 ft.) mobile-grade referencing
system.
Additional Operator’s Umbrella Option
This is a 1372 mm (54 in.) square umbrella with mounting hardware supplemental to the
standard single unit to accommodate the second operator’s control station.
17
INTRODUCTION
IDENTIFICATION OF MAJOR COMPONENTS
Figure 7
2
3
4
5
6
7
1
8
10
9
Legend:
18
1.
Hopper
6.
Seat
2.
Conveyor
7.
Screed
3.
Flow Gates
8.
Screed Tow Point
4.
Direction/Speed Lever Control Pedestal
9.
Front Wheel Bogies
5.
Main Console
10.
Rollers
SECTION 1 - SAFETY
1-1
Section 1
SAFETY
SAFETY
BE AWARE OF SAFETY INFORMATION
This is the Safety Alert Symbol. When you see this symbol in this manual, be alert to the
potential for personal injury. Follow recommended precautions and safe operating practices.
UNDERSTAND SIGNAL WORDS
A signal word - DANGER, WARNING, or CAUTION - is used with the safety-alert symbol.
Signal words are categorized and used in a strict hierarchy of seriousness, depending on the
nature of the hazard and whether or not it is life threatening to personnel, injurious to personnel
or potentially damaging to property, equipment or could have an adverse effect on the
machines ability to perform in an efficient manner.
DANGER, WARNING, or CAUTION safety labels may be located near specific hazards, and
are also used in this manual to alert the reader to specific hazards - as defined below.
This is the SAFETY ALERT SYMBOL. It is used to
alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol
to avoid possible injury or death.
!
DANGER
DANGER is used to indicate the presence of a
hazard which will cause severe personal injury or
death if the warning is ignored.
(Red Background)
!
WARNING
WARNING is used to indicate the presence of a
hazard which can cause severe injury or death if
the warning is ignored.
(Orange Background)
!
CAUTION
CAUTION is used to indicate the presence of a
hazard which will or can cause personal injury, or
property damage if the warning is ignored.
(Yellow Background)
NOTICE
NOTICE is used to notify people of installation,
operation, or maintenance information which is
important but not hazard related.
(Blue Background)
1-2
SAFETY
Section 1
OVERVIEW
Before you operate, maintain, or in any other way use this Paver/Finisher:
READ and STUDY this manual. KNOW how to safely use the paver/finisher’s controls and
what you must do for safe maintenance.
ALWAYS wear or use proper personal protective equipment required for your personal
protection.
If you have ANY QUESTIONS about the safe use or maintenance of this paver/finisher, ASK
YOUR SUPERVISOR OR CONTACT ANY INGERSOL-RAND DISTRIBUTOR. NEVER
GUESS-ALWAYS CHECK!
WARNINGS
The following conventions are used in this manual to designate instructions of particular
importance.
NOTE: Refers to special information on the efficient use of the machine.
NOTICE: Denotes special nonhazardous related information.
CAUTION: Refers to orders and prohibitions directed towards preventing product/property
damage and/or degraded machine performance.
WARNING: Refers to orders and prohibitions designed to prevent personal injury and/or
death.
GENERAL
Ingersoll-Rand cannot foresee all possible circumstances that might lead up to a potential
hazard. Therefore, the combination of warnings listed in this manual and those placed on the
machine itself are not intended to be all inclusive.
Operators and maintenance personnel must be alert to recognize and avoid potential hazards.
They should also have comprehensive training, required skills and necessary tools to properly
perform their functions.
The machine was built in accordance with state-of-the-art standards and recognized safety
rules. Nevertheless, its misuse or careless operation may constitute a life-threatening risk to
the user or to third parties and may cause damage to the machine or other material property.
The machine must be used only as described in the operating and control sections of this
manual. The machine must only be operated by safety-conscious persons who have been
properly trained in operating the machine and are fully aware of the safety issues associated
with its operation. Any functional disorders, especially those affecting the safety of the
machine, must be corrected immediately.
1-3
Section 1
SAFETY
The machine is designed exclusively for the Pave/Finish of asphaltic road construction
materials. Use of the machine for purposes other than that mentioned, such as towing other
vehicles/equipment is considered contrary to its designated use. The manufacturer/supplier
cannot be held liable for any damage resulting from such use. The risk of such misuse lies
entirely with the user.
Operating the machine within the limits of its designated use also involves compliance with the
inspection and maintenance directives contained in the operating section of this manual.
SELECTION AND QUALIFICATION OF PERSONNEL
Work on and with the machine must be performed by qualified personnel only. Statutory
minimum age limits must be observed.
Individual responsibilities of the personnel responsible for operation, setup, maintenance and
repair of the machine should be stated clearly.
Define the machine operator’s responsibilities: not only pertaining to the machine’s operation,
but also with regard to observing traffic regulations. The operator should have the authority to
refuse instructions by third parties that are contrary to safety.
Do not allow persons being trained or instructed in the operation or maintenance of the
machine to work without permanent supervision by an experienced person.
Work on the electrical system and equipment of the machine must be done only by a skilled
electrician or by instructed persons under the supervision and guidance of a skilled electrician
and must be in accordance with electrical engineering rules and regulations.
Work on the chassis, brake, hydraulic and steering systems must be performed by skilled
personnel with special knowledge and training for such work.
ORGANIZATIONAL MEASURES
Operation and Maintenance manuals MUST always be available at the site where the machine
is used.
OBSERVE AND INSTRUCT the user in all other generally applicable legal and mandatory
regulations relevant to accident prevention and environmental protection. These compulsory
regulations may also deal with the handling of hazardous substances, issuing and/or wearing
of personal protective equipment, and traffic regulations.
SUPPLEMENT operating instructions with detailed working instructions pertaining to the
specific work location.
ALWAYS be sure that persons entrusted with work on the machine have read the operating
instructions and, in particular, the chapter on safety before beginning work. Reading the
instructions after work has begun is too late. This is especially important for persons who work
only occasionally on the machine, e.g. during set up or maintenance.
MAKE CERTAIN personnel are working in compliance with the operating instructions and are
alert to risks and safety factors.
1-4
SAFETY
Section 1
ALWAYS tie back or otherwise secure long hair, wear close-fitting garments and avoid
wearing jewelry such as rings, bracelets and necklaces. Injury may result from clothing, hair,
or jewelry being caught up in the machinery.
USE protective equipment wherever required by the circumstances or by law.
OBSERVE all safety instructions and warnings attached to the machine and in this manual.
BE SURE all safety instructions and warnings attached to the machine are complete and
perfectly legible.
STOP the machine immediately in the event of any malfunction. REPORT the malfunction to
the proper authority/person. The continued operation of a machine that is not working properly
may cause extensive damage to the machine or significantly increase the hazards to operating
personnel from abnormal operating conditions.
NEVER provide service or maintenance to the machine in ANY manner other than that which
is described in this manual.
NEVER make any modifications, additions or conversions to the machine which might affect
safety without the manufacturer’s approval. This applies to the installation and adjustment of
safety devices and valves as well as to welding work on load bearing elements.
ALWAYS ADHERE to prescribed intervals or those specified in the operating instructions for
routine checks and inspections. Consistently performing scheduled maintenance will extend
the life of your machine.
MANDATORY SAFETY MEASURES
Never clean, lubricate or service the paver/finisher when it is running.
Always operate the SmokEater® Ventilation Control System when placing paving materials
which produce fumes.
Do not operate the machinery while under the influence of drugs or alcohol.
Use safety items (hard hat, safety boots, eye and ear protection, etc.) as appropriate or
required.
Do not wear radio or music headphones while operating the machines.
Do not wear jewelry while operating the machine.
Re-install safeguards and shields securely and clear all maintenance tools before starting the
engine after maintenance.
If you have ANY QUESTIONS about the safe use or maintenance of this machine, ASK YOUR
SUPERVISOR OR CONTACT ANY INGERSOLL-RAND BLAW-KNOX DISTRIBUTOR.
NEVER GUESS-ALWAYS CHECK!
Failure to adhere to these instructions may result in serious injury or even death.
1-5
Section 1
SAFETY
LOADING AND UNLOADING
Loading Dock with Ramp (Preferred Method)
The easiest and safest method for unloading your Ingersoll-Rand Blaw-Knox PF-161 from a
truck is to drive it off onto a loading dock that is level with the truck bed. Before unloading:
•
Remove any loose parts from the truck deck or machine.
•
Release and remove any tie-down equipment, and chocks and blocks under the
machine frame.
•
Position the rear of the trailer firmly against the loading dock.
•
Engage the truck’s parking brake.
Alternate Ramp Method
If a loading dock is not available, a ramp or set of ramps positioned at a 12° angle may be
used. Ramp(s) must be rated to support the weight of the machine, 18T (20 tons).
•
Remove any loose parts from the truck deck or machine.
•
Release and remove any tie-down equipment, and chocks and blocks under the
machine frame.
PRE-START INSPECTION
INSPECT your paver/finisher daily. Ensure that the routine maintenance and lubrication are
being dutifully performed. Have any malfunctioning, broken, or missing parts repaired or
replaced before use. Refer to the Maintenance Schedule located in Section 5 of this manual.
VERIFY that all instruction and safety labels are in place and readable. These instructions are
as important as any other equipment on the paver/finisher. Refer to the decal location drawing
later in this Section.
BE MINDFUL of your surroundings before fueling. NEVER fill the fuel tank with the engine
running, while the machine is located near an open flame or while operating personnel are
smoking. Smoking is PROHIBITED within 15 M (50 FT.) of the machine while fueling.
ALWAYS wipe up any spilled fuel.
CHECK the Front Wheel assist relief pressure. It should be set according to the operating
surface.
CHECK for any maintenance and repair WARNING tags placed on the machine. DO NOT
operate the paver/finisher until repairs have been made and the WARNING tags have been
removed by authorized personnel.
KEEP the operator’s platform CLEAN. REMOVE any dirt, debris or foreign material from the
operator’s platform to reduce the danger of slipping.
KNOW the location of the Emergency Shut-Down Control.
1-6
SAFETY
Section 1
ALWAYS know the capabilities and limitations of your equipment in terms of speed,
gradeability, steering and braking.
BE AWARE of the dimensions of your paver/finisher-height and weight-as well as your screed
extension’s dimensions and weight or height and dimensions of the operator’s umbrella.
CHECK for any operating conditions that could be dangerous such as holes, banks,
underground culverts, manhole covers, water melt pits, curbs and/or street boxes.
CHECK the Parking Brake on flat open ground. Low speed range (Low Motor Shift Switch
position) should not overpower the brake. If the Parking Brake can be overpowered, brake
packs inside of the final drive planetaries must be repaired. Parking Brake is not adjustable.
SAFETY INSTRUCTIONS GOVERNING OPERATION
AVOID any operational mode or procedure that might sacrifice safety.
TAKE all necessary precautions to ensure that the machine is used only when in a safe and
reliable condition.
OPERATE the machine only if all protective and safety oriented devices, such as removable
safety devices, emergency shut off equipment, soundproofing elements and exhausts, are in
place and fully functional.
CHECK the seat belt regularly for wear or damage. Inspect the belt hardware and fabric.
Replace if the hardware is damaged or strap is nicked, frayed or loose stitching is found.
START the machine from the driver’s seat only and FASTEN the seat belt before starting the
engine.
WATCH the indicators during start up and shutdown procedures in accordance with the
operating instructions. Refer to the lamp/indicator light check procedures in the Section 5 of
this manual.
CHECK the surrounding area for pedestrians. MAKE SURE no one is at danger or risk before
starting up or setting the machine in motion.
CHECK that braking, steering, signalling and lighting systems are fully functional before
starting work or traveling with the machine.
CHECK that accessories have been safely stowed away before setting the machine in motion.
OBSERVE the valid traffic regulations when traveling on public roads. ALWAYS MAKE SURE
the machine is in a condition compatible with these regulations.
ALWAYS SWITCH ON the lighting system in conditions of poor visibility and after dark.
MAKE SURE there is sufficient clearance when crossing underpasses, bridges and tunnels or
when passing under overhead lines.
1-7
Section 1
SAFETY
ALWAYS KEEP at a safe distance from the edges of building pits and slopes.
AVOID any operation that might be a risk to machine stability.
ALWAYS SECURE the machine against inadvertent movement and unauthorized use before
leaving the driver’s seat.
NEVER SHIFT the transmission on a grade without first stopping the machine and applying
the parking brake
Starting
ALWAYS USE hand rails and steps to get on and off the Paver/Finisher.
ALWAYS MAINTAIN a “three-point contact” when climbing onto or off of a Paver/Finisher.
READ and FOLLOW ALL instruction decals.
ALWAYS be seated with the seat belt on when operating the machine.
BEFORE attempting to start the engine, ENSURE that the DIrection-Speed lever is in the
NEUTRAL position.
START the engine from the operator’s position only.
NEVER jump start the machine directly to the starter or starter solenoid. SEVERE INJURY or
even DEATH could result from the machine lurching forward or reverse and running over the
person(s) attempting to jump start the machine. AVOID personal INJURIES by making sure
that the machine being jumped does not touch or come in contact with the machine supplying
the jump.
NEVER jump a frozen battery, it will EXPLODE.
While charging lead acid batteries generate explosive gases. Keep SPARKS, FLAMES and
lighted SMOKING material AWAY from BATTERIES.
ALWAYS wear safety glasses when working near batteries.
Proceed as follows when jump starting the machine:
1-8
•
Connect the Positive (+) terminal of the booster battery to the Positive (+) terminal of
the discharged battery.
•
Connect the Negative (-) terminal of the booster battery to the best ground point on
the machine away from the battery.
•
Follow all the recommended engine starting procedures.
•
Remove the jumper cables in the reverse order of their connection as soon as the
engine has started.
SAFETY
Section 1
Operating
ALWAYS make sure that no person or obstruction is in your line of travel before starting to
move the PAVER/FINISHER machine.
ALWAYS LOOK in all directions BEFORE changing your direction in travel.
NEVER CLIMB onto or off of the machine at any time while it is operating/running.
ALWAYS remain seated with your seat belt on when operating the paver/finisher. NO
EXCEPTIONS.
ALWAYS USE EXTREME CAUTION and be very observant when operating in close quarters
or congested areas.
KNOW and USE the hand signals required for particular jobs and know who has the
responsibility for signaling.
NO RIDERS. NEVER carry passengers.
NEVER allow anyone to stand within the paver/finisher “articulation area” with the engine
running.
KNOW the area in which you are working. Familiarize yourself with work site obstructions and
any other potential hazards in the area.
When the SmokEater® Ventilation Control System exhaust stack is installed, never attempt to
pass under low overhead obstructions, such as bridges or utility wires, without first confirming
there is adequate clearance. Always lower or remove the exhaust stack if there is any question
about clearance.
READ and FOLLOW ALL instruction decals.
Stopping
ALWAYS park the paver/finisher on solid level ground. If that is not practical, park the paver/
finisher at a right-angle to the slope and chock the wheels.
Reduce the travel speed by moving the Direction Speed Levers before stopping the machine.
To stop the machine, push the Direction-Speed Lever back to NEUTRAL. Push the Main
Switch OFF. The parking brake will automatically engage.
Before leaving the operator’s seat, ALWAYS BE SURE that all control switches are in the OFF
or NEUTRAL position and the engine is shut off.
Before leaving the operator’s seat MAKE CERTAIN that the hopper wings are lowered and the
screed is lowered or secured in the raised position.
ALWAYS mount and dismount the machine from the rear using the walkways, steps and
handrails provided. Never jump from the operators platform to the ground.
ALWAYS maintain a “three-point contact” when climbing onto or off of the paver/finisher.
USE proper flags, barriers and warning devices to warn others of your presence, especially
when parking in heavy traffic.
1-9
Section 1
SAFETY
Maintenance
In any work concerning the operation, conversion or adjustment of the machine and its safety
oriented devices or any work related to maintenance, inspection and repair, always observe
the start up and shutdown procedures set out in the operating instructions and the information
on maintenance work.
ENSURE that the maintenance area is adequately secured as outlined below.
If the paver/finisher is completely shut down for maintenance and repair work, it must be
secured against inadvertent starting by:
•
locking the principle control elements and removing the ignition key and/or
•
rotating the battery master switch to “OFF” and attaching a warning sign to the
battery master switch.
Before starting any work, check the de-energized parts for the presence of power and ground
or short circuit any parts found to contain residual power in addition to insulating adjacent live
parts and elements.
The electrical equipment of machines is to be inspected and checked at regular intervals.
Defects such as loose connections or scorched cables must be rectified immediately.
CARRY OUT maintenance and repair work only if the machine is positioned on stable and
level ground and has been secured against inadvertent movement.
ALWAYS USE the correct tools and workshop equipment when performing maintenance to
the machine.
KEEP all standing surfaces free from mud, dirt, snow and ice.
CLEAN the machine, at the end of each workday while the machine is still warm with diesel
fuel, kerosene or other appropriate (biodegradable) cleaning solution.
All residual asphalt materials should be removed from the paver, especially in the material
handling areas and the surfaces sprayed to eliminate any remaining residue. This leaves a
petroleum film on surfaces to reduce the potential for material sticking the next time the paver
is used. SPECIAL CARE MUST BE TAKEN with the engine and battery area so that cables
and/or hoses are not damaged or disconnected.
After cleaning, EXAMINE all fuel and hydraulic fluid lines for leaks, loose connections, chafe
marks and damage. REPAIR or REPLACE defective parts immediately.
ALWAYS TIGHTEN any screwed connections that have been loosened during maintenance
and repair.
ENSURE that all consumables and replaced parts are disposed of safely and with minimum
environmental impact.
Any safety devices removed during setup, maintenance or repair purpose MUST BE refitted
and CHECKED immediately upon completion of the maintenance and repair.
AVOID, whenever possible, servicing, cleaning, or examining the paver/finisher with the
engine running.
AVOID, whenever possible, servicing or providing maintenance unless the machine is
adequately secured against movement.
1-10
SAFETY
Section 1
NEVER fill the fuel tank with the engine running. Do not permit sparks, open flames or smoking
within 15 M (50 ft.) of the machine while refueling. Never refuel the machine with the screed
heaters operating. ALWAYS wipe up any spilled fuel.
DO NOT alter the engine’s governor settings from those indicated in the engine manual and
the engine option plate.
ALWAYS replace damaged or lost decals. It is dangerous to operate the machine without
these decals. Refer to the parts manual for the proper location and part number for all decals.
In order to ENSURE the SAFE OPERATION, optimum performance and to PROTECT your
WARRANTY, use only genuine Ingersoll-Rand replacement parts.
DISCONNECT the battery cables when working on the electrical system or when welding on
the machine.
BE SURE the battery area is well ventilated (clear of fumes) should it be necessary to connect
a jump battery or battery charger. Fumes from the battery can ignite by a spark and explode.
BE SURE the battery charger is “Off” when making the connections if battery charging is
required.
The electrical equipment of machines is to be INSPECTED and CHECKED at regular
intervals. Defects such as loose connections or scorched cables MUST BE RECTIFIED
IMMEDIATELY.
Welding, flame cutting and grinding work on the machine SHOULD ONLY BE DONE if
expressly authorized, as there may be a risk of explosion and fire.
Before beginning welding, flame cutting and grinding operations, clean the machine and its
surroundings from dust and other flammable substances and make sure that the premises are
adequately ventilated (risk of explosion). Hydraulic hose assemblies must be visually
inspected at regular intervals and immediately replaced if they show signs of chafing, cracking
brittleness, deformation, blistering, leakage, fitting separation, corrosion or other damages
which may affect their function and strength.
Do not work on hydraulic lines while the engine is running and the system is under pressure.
The hydraulic fluid remains under pressure long after the engine has been stopped. Do not
work on any hydraulic hose or fitting until the pressure has been relieved correctly.
Hot hydraulic fluid will cause severe burns. Wait for fluid to cool down before disconnecting
lines.
NEVER USE YOUR HANDS to check for hydraulic leaks when inspecting a hydraulic system.
Use a piece of cardboard an always wear gloves and eye protection.
Fluid penetration from a pin hole leak can cause severe injury or death. Get immediate
treatment if fluid has been injected under your skin.
DEPRESSURIZE ALL SYSTEM SECTIONS and pressure pipes (hydraulic system,
compressed air system) to be removed in accordance with the specific instructions for the unit
concerned before carrying out any repair work.
Hydraulic lines MUST BE laid and fitted properly. Ensure that no connections are
interchanged. The fittings, lengths and quality of the hoses must comply with the technical
requirements.
1-11
Section 1
SAFETY
When handling oil, grease and other chemical substances, OBSERVE the product related
safety regulations.
ENSURE that all consumable and replaced parts are disposed of safely and within
environmental regulations.
Work on the electrical system and equipment of the machine must be done only by a skilled
electrician or by instructed person under the supervision and guidance of a skilled electrician
and must be in accordance with electrical engineering rules and regulations.
If provided for in the regulations, the power supply must be cut off to parts of machines, on
which inspection, maintenance and repair work is to be carried out.
Be careful when handling hot consumables (risk of burning or scalding), and wear the
appropriate personal protective equipment.
HAZARDOUS SUBSTANCE PRECAUTION
The following information is provided to assist the owners and operators of Ingersoll-Rand
Blaw-Knox machinery. Further information may be obtained by contacting your Ingersoll-Rand
Blaw-Knox Road Machinery Equipment Distributor.
The following substances are used in the manufacture or produced during the operation of this
machine and may be hazardous to health if used incorrectly.
SUBSTANCE
Hydraulic Oil
Avoid ingestion, skin contact and breathing fumes.
Engine Lubricating Oil
Engine Fuel
Anti-Freeze
Rust Preventative
Electric Motor Dust
(Brushes/Insulation)
Avoid breathing dust during maintenance.
Battery Electrolyte
Engine Exhaust Fumes
1-12
PRECAUTION
Avoid breathing.
Avoid buildup of fumes in confined spaces.
Paving Mixtures
Preservative Grease
SAE Gear Oil
SAFETY
Section 1
WARNING OF SPECIAL DANGERS
When working with the machine, maintain a safe distance from overhead electric lines. If the
work is to be carried out close to overhead lines, the work equipment must be kept away from
them.
!
WARNING
Electrocution Hazard.
If your machine comes in contact with electric power lines, observe the
following:
•
Stay in the operators seat.
•
Warn other workers to stay away and do not touch any control or any part of
the machine.
•
If contact can be broken, drive the machine away from the danger zone.
•
If contact cannot be broken, stay in the operators seat until told that power is
off.
Failure to observe this admonishment could result in electrocution and
death.
!
CAUTION
Equipment/Property Damage.
Remove the exhaust stack if you have any doubts that it cannot pass
under electrical lines or under an overpass or bridge.
Failure to adhere to this admonishment could result in damage to the
paver/finisher and surrounding property.
Operate internal combustion engines and fuel operated heating systems only in adequately
ventilated areas. Before starting the machine in enclosed areas, make sure that there is
sufficient ventilation.
The following table provides a list of locations and quantities of labels used on the paver/
finisher. Use this table in conjunction with the illustrations on the following pages to visualize
where each label should be on the machine. It is your responsibility to maintain these
labels in a legible condition on the machine.
1-13
Section 1
SAFETY
Figure 1-1
1-14
SAFETY
Section 1
NO.
DECAL
NO.
REQ’D
LOCATION
1
CAUTION: Auto Brakes
2
Control Console
2
CAUTION: Before starting or leaving
Instructions
2
Control Console
3
WARNING: Travel Speed Shift
2
Control Console
4
WARNING: California Proposition 65 Warning
2
Hood Arrangement
5
WARNING: Avoid personal injury or death
1
Rear, under the seats
6
WARNING: Hot oil
1
Platform, near console base
7
WARNING: Avoid possible injury from runaway
machine
2
Operators’ seat or Hood
Arrangement
8
WARNING: Personal injury due to:
1
Hopper, front L & R side
9
WARNING: Cause of toxic fumes
2
Hopper, front L & R side
10
WARNING: Brake release, emergency towing
2
Steering Column or hood
arrangement
11
WARNING: Do not close the brake release
valve
1
12
WARNING: Keep from falling off platform
2
Direction-Speed Lever
Console, outside low, L & R
side
13
CAUTION: Operation precautions
1
Rear, under the seat next to
#17
14
WARNING: Hopper injury
2
Rear, upper part of hopper,
outside.
15
CAUTION: NO SMOKING
2
Rear, side under seat
16
WARNING: Hydraulic tank
1
Platform, near console base
17
WARNING: Slip and fall
1
1-15
Section 1
1-16
SAFETY
SAFETY
Section 1
1-17
Section 1
1-18
SAFETY
SECTION 2 - ASSEMBLY
2-1
Section 2
ASSEMBLY
ASSEMBLY
GENERAL
A Paver/Finisher shipped for use within the United States is normally shipped nearly
assembled for basic paving widths. Before paving can actually begin, some assembly must be
performed. The amount of assembly required depends on the number of options you plan to
use with your paver/finisher.
This section provides assembly guidelines to be used during this assembly process. It is
divided into two categories. The general assembly of the paver/finisher is addressed first. This
is the basic assembly required of all machines to get it “road ready” and prepared to perform
basic paving. Secondly, we address the installation of the available options for your paver.
These assembly instructions are separate stand alone procedures and apply only to Paver/
Finishers that have been purchased with the optional equipment being addressed.
GENERAL ASSEMBLY
As mentioned earlier, some basic assembly is required for all models and should be performed
completely before attempting to operate your paver/finisher in any fashion with the exception
of placing the machine in an appropriate work area. The guidelines are broken down into the
following tasks:
•
Before you begin
•
Unloading the machine
•
Installation of the steering guide
•
Installation of the edger-plate assemblies
•
Installation of the automatic feed control sensors
•
Installation of the muffler
After these items are installed, you will need to install any options you may have. These
guidelines are provided in a separate area of this section. First, perform the tasks listed above
as described in the following paragraphs.
Before you Begin
Before you attempt to perform any equipment assembly you will need to get the machine into
a suitable area for the task to be performed. The following instructions are provided as a guide
to this end. It is strongly recommended that only personnel experienced with this machine be
involved in these procedures. Inexperienced individuals may make errors that could damage
property and jeopardize personnel safety.
2-2
ASSEMBLY
Section 2
Selecting a Site for Assembly
Before you unload the machine, you may want to take the time to select an appropriate site
for the assembly work you will be performing. Some simple suggestions follow that will make
this task easier and more trouble free.
First, read this section in its entirety. Take the time to think about what you will have to
assemble. Consider all of the optional equipment you have ordered and what will be involved
in its installation and setup.
Next, select a suitable site for the tasks to be performed. Select a well-lit area with some
protection form the elements if possible. If that is not practical, do your best to select a dry,
level area where sure-footed workers will have adequate light to read and follow instructions,
select tools and read instruments.
Finally, take the time to gather an adequate set of tools for the job. This will ensure that the
task can be completed in a professional manner without needless interruptions.
Unloading the Machine
!
WARNING
Personal Injury/Property Damage
Do not allow inexperienced or untrained personnel to move this machine.
Only qualified individuals who have been properly trained should be
allowed to operate this machine, even for the simple task of relocating or
moving the machine.
Failure to adhere to this Warning could result in property damage, severe
physical injury or even death.
!
CAUTION
Equipment Damage
Make sure all fluid levels are adequate for operation. Check engine oil
levels before attempting to start the engine. If necessary, top fluid off
before beginning operation.
Failure to adhere to this Caution could result in equipment damage,
performance degradation or premature failure of mechanical
components.
2-3
Section 2
ASSEMBLY
You will probably have to unload the machine from a tractor-trailer, truck or a flat-bed railroad
car. The easiest and safest way to do this is to drive it off the transport vehicle onto a loading
dock that is level with the vehicle bed. To do this, perform Steps 1 through 25.
If no loading dock is available, you may use a set of ramp boards. Be sure the ramp boards
are of sufficient strength to support the weight of the machine. Set the ramp boards at an angle
of 12° or less. After the ramp boards are in place, perform Steps 1 through 25 to off load the
machine.
As a last resort, you could use a crane to unload the vehicle. Before attempting to lift the
machine, make sure you have removed any separate parts from the truck bed and removed
all equipment that secured the machine in the truck bed, including tie downs, chock blocks and
blocks under the frame. A crane with a 20-ton (18T) capacity is required. Position the lifting
sling properly so that the load will be centered. After the machine has been removed from the
transport and gently placed on the ground, perform Steps 3 through 25.
1. First remove any separate parts from the truck bed.
2. Remove all tie-down equipment, chock blocks and blocks under the frame.
3. Inspect the machine for damage that may have occurred in transit.
4. Inspect the area around the machine for signs of fluids. If there are signs of fluid
leaks, clean the area before proceeding and replace any lost fluid before
attempting to move the machine.
5. Check fluid levels, such as engine oil, hydraulic oil, etc.
6. Make sure the tires are properly inflated. If necessary add air before attempting
to move the vehicle.
!
CAUTION
Possible Equipment Damage
If the parts package sitting in the hopper cannot be removed before
starting the machine, make sure the CONVEYOR IS OFF.
Inadvertent operation of the conveyors may result in damage to
packaged material and the conveyors themselves.
7. Mount the machine using the steps and handrail provided at the rear of the
machine.
8. If necessary, install seats on the seat posts.
2-4
ASSEMBLY
Section 2
9. Unlock and open the cover (3, Figure 2-1) on the swing console to gain access
to the main control panel.
Figure 2-1
10. Position the main control panel to a position suitable for the side of the machine
you will be seated.
11. Position the Direction/Speed Control Lever (2, Figure 2-1) to the NEUTRAL
(centered) position.
12. Place all control switches on the main control panel to the OFF or centered
position.
13. Position the THROTTLE Switch (32, Figure 2-2) to the IDLE (center) position.
Figure 2-2
14. Position the TRANS Switch (20, Figure 2-2) to the LOW position.
15. Position the MOTOR Switch (21, Figure 2-2) to the LOW position.
2-5
Section 2
ASSEMBLY
16. At the Direction/Speed Control Lever to be used, rotate the hinged lockout plate
out of the way, so that the lever is free to move into the reverse range.
17. Pull the Engine Kill Button (19, Figure 2-2) all the way out.
18. Push the STARTER Button (18, Figure 2-2). The engine should start and come
up to speed. Note that the engine will not start if the Direction/Speed Control
Lever is not in the NEUTRAL position.
19. Wait approximately 3 minutes to allow the engine to warm up.
20. Position the screed to a position above the ground, using the SCREED Control
Switch (24, Figure 2-2). Make sure the screed cylinders are retracted
sufficiently to engage the locking support brackets (1, Figure 2-3) on the lefthand and right-hand hydraulic screed cylinders.
Figure 2-3
21. Make sure the SCREED Control Switch (24, Figure 2-2) is returned to the
HOLD (center) position after you have positioned the screed to the desired
height.
22. Manually secure the screed in it’s elevated position using the locking support
brackets (1, Figure 2-3) on the left-hand and right-hand hydraulic screed
cylinders.
NOTE: The further the Direction/Speed Control Lever is moved from
NEUTRAL the greater the machine velocity will be.
23. Move the Direction/Speed Control Lever (2, Figure 2-1) in the FWD or REV
direction as necessary to move the machine in the desired direction.
24. To stop the machine, bring the Direction/Speed Control Lever (2, Figure 2-1)
back to the NEUTRAL position.
25. When the machine is positioned in an appropriate area to commence
assembly, place the Direction Speed Control Lever (2, Figure 2-1) to the
NEUTRAL position and fully depress the Engine Kill Button (19, Figure 2-2) on
the main control panel. The parking brake will automatically engage.
2-6
ASSEMBLY
Section 2
Installation of the Steering Guide
The following provides a guideline to be followed when installing the steering guide on the
Paver/Finisher.
1. Decide which operating position on the deck will be used (right-hand or lefthand). This decision should be based on location of a ground steering
reference in relation to the direction of the machine travel when paving. Typical
references are road center line, existing mat edge, curb stringline, side of
building, etc.
2. Install the steering guide (1, Figure 2-4) through the respective right-hand or
left-hand push-plate bracket (2, Figure 2-4).
Figure 2-4
3. The chain end is extended for ground-level references. The spring end can be
used up against high curbs or sides of a building.
4. The steering guide can be extended to align with the mat edge being placed by
the screed.
5. Tighten the bracket set screw to secure in the selected position.
2-7
Section 2
ASSEMBLY
Installation of the Edger-Plate Assemblies
Left-hand and right-hand edger-plate assemblies mount on the respective ends of the screed.
The following provides a guideline to be followed when installing these edger-plate assemblies
on your screed.
NOTE: The left-hand frame contains three holes, while the right-hand
frame contains three mounting mandrels.
1. Begin installing the edger-plate frames (4, Figure 2-5) onto their respective
ends of the screed by installing the three mounting mandrels (they are shipped
loose); two large (3, Figure 2-5) and one small (6, Figure 2-5) in the left-hand
outer end of the screed.
Figure 2-5
2. Align the three mandrels and the three holes of the screed and edger-guide
frames.
3. Insert the mandrels through the holes until the mandrel slots are exposed on
the opposite side of the mounting member. Refer to Figure 2-6 for details of the
wedge pin attaching and adjusting assemblies.
NOTE: Use the slide hammer provided to drive the wedge-keeper pins
into the slots securing the edger-plate assemblies in position.
4. Fasten the edger-plate frames (4, Figure 2-5) on the outer end of the screed
using the wedge keepers (2, Figure 2-5).
NOTE: When installing the edger-plate assemblies for the first time it may
be necessary to adjust for proper alignment with the screed.
2-8
ASSEMBLY
Section 2
NOTE: Mounting mandrels have angles slots. The large opening must be
up to prevent jamming of the wedge.
5. Adjust the lower-rear and the upper mounting mandrels (5, Figure 2-6).
Figure 2-6
NOTE: Special wrenches are provided to turn the lock nut and adjust the
nut.
6. Loosen the two lock nuts (3, Figure 2-6) and the two mandrel nuts (2, Figure 26) while the wedge keepers (1, Figure 2-6) remain loosely installed.
7. Turn the adjusting nut (4, Figure 2-6) at each location and observe the eccentric
action on the edger-guide frame. Turning the lower-rear adjusting nut causes
the rear of the edger-guide frame to move up-down.
8. Adjust the position of the edger-guide mounting plate until it is perpendicular
with the bottom of the screed plate using these adjusting nuts.
9. Set all three wedge keepers firmly in the mounting mandrel.
10. Tighten the two nuts and lock nuts (2 and 3, Figure 2-6) against the screed
frame to maintain the setting you just achieved.
11. Slide the edger-plate (4, Figure 2-7) rearward into the edger-guides (1, Figure
2-7) and secure with the guide hardware (11, Figure 2-7).
12. Assemble the upper and lower-spring-guide tubes (6 and 7, Figure 2-7) with
two springs inside. The upper tube screen applies pressure on the bottom of
the edger-guide as shown.
2-9
Section 2
ASSEMBLY
13. The lower tube (7, Figure 2-7) should be mounted on the studs on the bottom
rail of the edger-plate.
14. Attach the edger-plate chains (8, Figure 2-7) to the jack hooks.
Figure 2-7
Installation of the Automatic Feed Control Sensors
Operation of the left-hand and right-hand auger/conveyor system is controlled either by the
paddle sensors or the Ultra 3s (Ultra Sonic Sensors) installed at the outer ends of the
respective auger system.
Installation of the Paddle Sensors
The following steps represent a guide for the installation of the paddle sensors. If you are going
to use the Ultra 3s, ignore this paragraph. Installation instructions for the Ultra 3s are provided
in the next paragraph, beginning on page 2-12.
NOTE: If you will be using a OmniScreed 1A or 3/6 Hydraulic Screed
extensions, place the paddle sensors in such a manner that they will
travel in and out on the extensions to accurately measure the head of the
material at the outer extremities of the screed. See the paragraph for
installation of these options for instructions on how-to-properly place
these sensors.
2-10
ASSEMBLY
Section 2
1. Mount the paddle sensors (1, Figure 2-8) on the main frame for basic-width
paving or on the outer ends of the auger guards/tunnels for extended-width
paving.
Figure 2-8
NOTE: Step 2 below is general in nature and will position the paddle
sensors at a typical starting point. Usually, additional adjustment is
required for optimum material control. Factors such as paving width,
depth and material composition all affect the sensor’s performance.
Some experimentation is usually necessary to obtain the best possible
position and orientation.
2. The location of the paddle sensors with respect to the ground, controls the head
of the material. Perform the following to set the height of the paddle sensors:
NOTE: There must be adequate clearance between the edger-plates and
the sensors to allow for unrestricted movement.
a. Loosen the thumb screw that secures the paddle sensor in the vertical
plane.
b. Raise the sensors in their mounting brackets so that the bottom edge of the
sensor is 102 mm (4-in.) from the surface of the ground.
c. Verify that the sensor paddles hang vertically and are angled up to
approximately 15° rearward.
d. Make sure the paddle sensors swing up parallel to the edger-plates.
e. Tighten the thumb screw securing the paddle sensor in place after all of the
above conditions are met.
2-11
Section 2
ASSEMBLY
!
CAUTION
Equipment Damage.
Take care to avoid cable routings which may pinch or strain the wire or
plug.
Failure to do so may result in damage to cable or plug resulting in system
failure or degraded performance.
3. Lead the sensor cables (1, Figure 2-9) outside of the side arms to the cleats (2,
Figure 2-9) and then plug into the respective left-hand or right-hand receptacles
(3, Figure 2-9) on the rear bulkhead.
Figure 2-9
Installation of Ultra 3s Ultra Sonic Sensors
The following provides a guideline for installing the Ultra 3s sensor system on the Paver/
Finisher.
1. Mount the Ultra 3s controllers (2, Figure 2-10) on the upright blades (3, Figure
2-10) at the left-hand and right-hand upper corners of the tractor.
2. Connect the plugs from each controller into their respective receptacles on the
rear tractor frame (1, Figure 2-10).
3. Install the Ultra 3s sensors (1, Figure 2-11) on the left-hand and right-hand
edger-guides (2, Figure 2-11) keeping the following in mind:
2-12
ASSEMBLY
Section 2
•
Position the sensors forward of the normal head of material and aim near the top
of the material pile at a right angle.
•
Sensors should be located approximately 381 mm (15-in.) from the surface when
the maximum head of material is present in front of the screed. The maximum
desirable head of material occurs when the paving material just covers the auger
shaft over its entire length.
Figure 2-10
Figure 2-11
2-13
Section 2
ASSEMBLY
Muffler Installation
Paver/Finishers are typically shipped without a muffler installed because it is impossible at the
time of manufacture to determine the specific requirements of your individual machine which
depends primarily on where in the country or world it’s going to be placed in service. Your
dealer can assist you in resolving these requirements and selecting the appropriate muffler/
exhaust system that will work properly with your paver/finisher while meeting your specific
operational needs.
OPTIONAL INSTALLATION GUIDELINES
The purpose of this second portion of the assembly section is to provide guidelines for the
installation of the optional features selected for your machine. These guidelines are broken
down as follows:
•
Installation of the cut-off plate
•
Installation of additional augers (for extended paving width)
•
Installation of 1 foot bolt on screed extension
•
Installation of 18-inch tapered-joint extension
•
Installation of the 8-ft. wedge-lock screed
•
Installation of the Ultra 4 Sonic averaging system and sonic joint matcher
•
Installation of the AGS (7.5) controls
Installation of the Cut-off Plate
NOTE: Be sure to remove the wear strips from the bottom of the edgerplates before attempting to install the cut-off plates.
The following provides guidelines for the installation of cut-off plates. Cut-off plates are used
to reduce the standard 2.44 meter (8-ft.) paving width in 76-mm (3-in.) increments up to 610mm (24-in.) increments.
1. Remove the wear strips from the edger-plates.
2-14
ASSEMBLY
Section 2
2. Install the cut-off plates (1, Figure 2-12) on the bottom of the edger-plates, as
shown in Figure 2-12.
Figure 2-12
Installation of Additional Augers
The following provides guidelines for the installation of additional augers. When paving at a
constant extended width, the installation of additional augers and tunnels will improve material
distribution to the screed extensions and help to maintain a proper head of material. Read
these instructions in their entirety before attempting to install any additional auger lengths. The
following paragraphs explain some basic concepts that must be understood before you can
expect to perform these procedures in an efficient manner.
2-15
Section 2
ASSEMBLY
The exploded view shown in Figure 2-13, which is the left-hand side assembled for 16-ft.
paving, typifies the use of all components required to reach various extended widths. Figure
2-13 illustrates the 16-ft. arrangement going together in four stages.
Figure 2-13
2-16
ASSEMBLY
Section 2
Figure 2-14 illustrates auger extension components needed for various specific extended
widths from 10-feet to 18-feet. These illustrations should be used to identify the exact parts
and quantities required for all extended widths.
Figure 2-14
NOTE: Arrangement dimensions are assumed to be symmetrical about
the center of the main screed.
•
For odd dimensions paving widths, always use the configuration shown for the next
smaller even dimension arrangement (i.e., for 17-ft. wide paving assemble as shown
for 16-ft.).
2-17
Section 2
ASSEMBLY
•
If offset paving is to be performed, determine the 1/2 dimension for each side of the
machine and assemble the augers, tunnels and guards according to the appropriate
illustration.
•
For 9 ft. through 11-ft. paving, the kickout augers work satisfactorily.
•
10-ft. paving will work as illustrated or could be accomplished by offsetting 2-ft. to one
side and assembling that side only, according to the 12-ft. arrangement.
•
11-ft. paving could be accomplished by offsetting 3-ft. and assembling according to
the 12-ft. arrangement or it could be accomplished by offsetting 3-ft. and assembling
according to the 14-ft. arrangement on either the left or right side.
There are three types of auger tunnels:
•
The inner short stepped tunnel (5, Figure 2-13) comes in both left-hand and righthand versions.
•
The middle long tunnel (2, Figure 2-13) which supports the additional auger bearing
(8, Figure 2-13) also comes in left-hand and right-hand versions.
•
The outer short tunnel (1, Figure 2-13) can be mounted on either side. Short and long
flaps (7 and 10, Figure 2-13) install on the bottom of the respective tunnels.
For paving width of 16-ft. and beyond, forward and upper bracing is required to maintain
adequate rigidity in the extended auger/tunnel structure. The forward (3, Figure 2-13) and
upper (4, Figure 2-13) braces are detailed in Figure 2-14 for both medium and wide paving
widths.
Augers consist of cast, 180° auger segments which install staggered, back-to-back with shaft
covers shown. There are long auger segments (11, Figure 2-13) with long cast shaft covers
(12, Figure 2-13) and there are also short auger segments (13, Figure 2-13) backed by short
covers (14, Figure 2-13). Depending on the width to be assembled, inner tubes (15, Figure 213), intermediate shafts (16, Figure 2-13) and outer tubes (17, Figure 2-13) will be required for
mounting of the auger segments. If the paving width is to be 14-ft. or more, support bearings
(8, Figure 2-13) are also required.
Perform the steps outlined below to install an auger extension:
NOTE: Auger-extension flights are directional (left-hand and right-hand)
and must be assembled on the correct side of the machine to feed
material outward. Make sure they are installed properly by comparing the
direction of the extension to that of the basic augers.
2-18
ASSEMBLY
Section 2
!
WARNING
Personnel Injury
Never use auger-guard extensions without appropriate auger guards.
Always install the left-hand and right-hand auger guards (7 and 8, Figure
2-13) as shown for maximum safety.
Failure to do so may result in serious personnel injury or even death.
1. Remove the kickout auger segments (1, Figure 2-15) from the end of the basic
auger shaft.
Figure 2-15
2. Install auger tunnels, (2, Figure 2-16) and bottom flaps (3, Figure 2-16). Refer
again to Figure 2-14 for specific components needed to reach various widths.
Figure 2-16
3. Assemble auger shafts and tubes (4, Figure 2-17), including support bearings
(5, Figure 2-17).
2-19
Section 2
ASSEMBLY
4. Attach auger guards (6, Figure 2-17) to auger tunnels.
Figure 2-17
5. Assemble auger segments (7, Figure 2-18) and corresponding shaft covers (8,
Figure 2-18) on the shafts.
Figure 2-18
6. Install forward and upper braces (9 and 10, Figure 2-19) to maintain rigidity
Figure 2-19
2-20
ASSEMBLY
Section 2
Installation of 1-foot Bolt-on Screed Extension
The 1-ft. bolt-on screed extension is an add-on for the UltiMat® Screed. The 1-ft. bolt-on
extension (1, Figure 2-20) is an ambidextrous extension that bolts on to the end of the primary
extension (2, Figure 2-20). This extension features electric heat, an adjustable pre-strike-off
plate and an adjustable angle-of-attack for the screed plate. The edger-plate assembly
(3, Figure 2-20) then bolts onto the outboard edge of the bolt-on extension.
Figure 2-20
The following steps provide a guideline for installation of the 1-foot, bolt-on screed extension.
1. Fully extend the primary extension where the 1-foot bolt-on extension will be
mounted.
2. Remove the edger-plate assembly on that side. Four cap screws attach the
edger-plate frame to the end of the extension.
3. Lower the screed to the ground.
4. Align the bolt-on extension so that the holes in the extension frames match.
2-21
Section 2
ASSEMBLY
5. Insert one cap screw (1, Figure 2-21), one hardened washer and one lock
washer into each of the four mounting holes. Snug the cap screws, but do not
tighten yet.
Figure 2-21
6. Raise the screed and secure it in position using the supports on the screed lift
cylinders.
7. Check the vertical alignment of the bolt-on extension compared to the primary
extension screed plate and adjust, as necessary.
8. Rotate the adjustment link (4, Figure 2-20) to match the angle-of-attack on the
bolt-on extension with the angle-of-attack on the primary extension.
9. Torque the cap screws (1, Figure 2-21) to 271 N•m (200 lb.-ft.) when satisfied
with the alignment achieved in Step 8 above.
10. Locate the harness supplied in the bolt-on extension kit.
11. Connect the heat mat on the bolt-on extension into the power circuit using the
harness.
2-22
ASSEMBLY
Section 2
12. Connect this harness to the available clip on the primary extension power
harness.
13. Set the height of the bolt-on extension pre-strike off 6 mm (1/4-inch) above the
bottom of the screed plate as shown in Figure 2-22.
Figure 2-22
14. Bolt the edger-plate to the outboard side of the bolt-on extension, using four
cap screws, four hardened washers, four lock washers and four hex nuts.
15. Reinstall the vibrator cover on the back of the primary extension.
2-23
Section 2
ASSEMBLY
Installation of the 18-inch Tapered-Joint Extension
The 18-inch (475 mm) bolt-on extension (1, Figure 2-23) is a right-handed or left-handed
extension that bolts onto the end of the primary extension. This extension can create a tapered
wedge up to 152 mm (6-in.) tall with no notch, or a tapered wedge up to 127 mm (5-in.) tall
with a maximum 25 mm (1-in.) notch. Refer to Figure 2-24.
Figure 2-23
Figure 2-24
1. Fully extend the primary extension where the 18-inch, tapered-joint extension
will be mounted.
2. Remove the edger-plate assembly on that side. Four cap screws attach the
edger-plate frame to the end of the extension.
3. Lower the screed to the ground.
4. Align the 18-inch tapered-joint extension so that the holes in the extension
frames match.
2-24
ASSEMBLY
Section 2
5. Insert one cap screw, one hardened washer and one lock washer into each of
the five mounting holes (1, Figure 2-25).
Figure 2-25
6. Snug the cap screws, do not tighten completely at this time.
7. Raise the screed and secure it in position using the supports on the screed lift
cylinders.
8. Check the vertical alignment of the 18-inch tapered-joint extension compared
to the primary extension screed plate and adjust as necessary.
9. Torque the cap screws to 271 N•m (200 lb.-ft.) when satisfied with the
alignment achieved in Step 8 above.
10. Bolt the edger-plate to the outboard side of the 18-inch, tapered-joint extension,
using four cap screws, four hardened washers, four lock washers and four hex
nuts.
11. Reinstall the vibrator cover on the back of the primary screed extension.
2-25
Section 2
ASSEMBLY
Installation of the 8-foot Wedge-lock Screed
The following provides a guideline for installation of the 8-ft. wedge-lock screed on the PF-161
paver/finisher. Read these guidelines in their entirety before attempting to install the wedgelock screed.
1. Position the paver/finisher with the screed in a manner that will facilitate the
installation of the 8-ft. wedge-lock screed.
2. Connect the tow-point cylinder (7, Figure 2-26) to the screed side arm
(8, Figure 2-26) as follows:
a. Insert the clevis pin to connect the tow-point cylinder and screed side arm,
position washers.
b. Insert the cotter pin at the bottom of the cylinder.
Figure 2-26
3. Connect the screed lift cylinders (5, Figure 2-27) at the lower end of the cylinder
as follows:
a. Position cylinder (5, Figure 2-27) over the mounting block (8, Figure 2-27).
b. Drive the clevis pin (7, Figure 2-27) through the cylinder bracket and the
mounting block (8, Figure 2-27).
2-26
ASSEMBLY
Section 2
c. Secure by inserting the cotter pin (6, Figure 2-27) at the bottom of the
cylinder.
Figure 2-27
4. Connect the side arms to the tow points as follows:
a. Insert the clevis pin (3, Figure 2-29) into the side-arm cylinder (4, Figure 2-29).
Figure 2-28
b. Attach to side arm using nut, bolt and front guide roller (2, Figure 2-28).
2-27
Section 2
ASSEMBLY
5. Connect the fuel cap hose (1, Figure 2-29) to the rear bulkhead of the tractor
which supplies fuel to the screed burners
Figure 2-29
6. Connect all hydraulic connections.
7. Connect all electrical connections.
Installation of Ultrasonic 4 Sonic Averaging System/Sonic Joint Matcher
This system is also known as the Automatic Level Control or simply the Joint Matcher. The
system controls the elevation of the mat being placed on one side (single) or both sides (dual)
of the paver/finisher with respect to a reference surface such as an adjacent mat or curb. It
controls the screed by automatically raising and lowering the tow point of the screed side arm
or, in the case of dual operation, both side arms.
The following steps provide a guideline for the installation of the Automatic Level Control (Joint
Matcher) system. During the performance of this procedure, keep in mind that the sensor may
be installed on either side depending on the location of the reference surface and the
anticipated direction of travel.
2-28
ASSEMBLY
Section 2
Perform the steps below to install the system:
1. Install the sensor as shown using the screed end tube (2, Figure 2-30),
mounting hardware (3, Figure 2-30) and jack (4, Figure 2-30) to reach the
reference surface (just outside the paver’s edger-plate).
Figure 2-30
2. Jog the cylinders up or down until the holes in the side arm and side arm guide
line up (5, Figure 2-32).
Figure 2-31
2-29
Section 2
ASSEMBLY
NOTICE
The step below applies only to single-sensor systems. And only the
opposite side of the machine from the sensor is affected.
3. When using a single sensor, lock the side arm located on the opposite side of
the machine in the centered position, using the hand valve (6, Figure 2-31).
Turn the valve off by moving it to the closed position.
4. Set the Mode Switch (7, Figure 2-30) on the sensor to the MONITOR position.
5. Install the sensor on the jack and plug the cord into the receptacle (7, Figure 231).
6. Jack the sensor down until the shoe rests on the reference surface in a trailing
direction.
7. With the paver ignition turned ON, adjust the sensor up or down while watching
the lights (9, Figure 2-30) until they both become extinguished. The sensor is
now nulled with the cylinder.
NOTE: Do not lock either side-arm cylinder after centering when using
dual controls.
8. If dual sensors are to be installed, repeat Steps 1 through 8 above on the
opposite side of the machine.
!
CAUTION
Before moving the paver around on the job, raise the sensor and secure
it for adequate ground clearance.
Failure to do so may result in damage to the sensor.
9. Set the Mode Switch (7, Figure 2-30) on the sensor to the AUTO position. The
system is now ready for paving.
2-30
ASSEMBLY
Section 2
Installation of the Ags (7.5) Controllers
The AGS 7.5 Grade/Slope controllers (2, Figure 2-32) are multipurpose control units that
function as either independent grade or independent slope controllers. Perform the following
to install these controllers
Figure 2-32
1. Position the controller on the top of the control station (1, Figure 2-32) and
secure in place using the latches on each side of the control station (3, Figure
2-32).
2. Plug one end of the cable into the control station (4, Figure 2-32) and the other
end into the receptacle of the sensor.
2-31
Section 2
2-32
ASSEMBLY
SECTION 3 - OPERATING
CONTROLS AND INSTRUMENTS
3-1
Section 3
DIRECTION-SPEED CONTROL LEVERS
The Direction-Speed Control Consoles have a Reverse Lockout (1, Figure 3-1), and a hinged
face plate which is used to prevent the Direction-Speed Control Levers from going in reverse.
The Direction-Speed Control Levers (2, Figure 3-1) are mechanical actuators which control the
direction of the machine travel FORWARD-STOP-REVERSE and vary the speed within the
limits of the 2-speed traction drive motor and single or 2-speed transmission (dependant on
model). An instruction plate indicating these positions is attached to each console.
The Direction-Speed Control Levers must be in NEUTRAL to start the engine.
Figure 3-1
Steering Units
The steering units (3, Figure 3-1) are both active full time.
3-2
Section 3
MAIN CONTROL PANEL
The majority of vehicle controls and indicators are located on this common, center-mounted
swing console panel with position lock. Refer to Figure 3-2 and Figure 3-4 for various views of
this panel followed by a brief explanation of each control and indicator located on the panel
itself. The main control panel itself is located between the two driver/operator control stations
and is locked in place by a cotter pin so that the control panel is positioned at one of the control
stations on one side or the other of the vehicle. This allows for easy setup between the two
seats.
This panel provides both control stations with electrical switch control of the following:
Main Power
Starter
Throttle
Horn
Shifting of Traction-Drive Motors
Right and Left-Side Feed System Function
Screed Lift
Auger Lift
Folding Hopper
Flowgates
Screed Vibrator Function
Parking Brake
Traction Lock System
Pivot Steering
Optional Truck Hitch
Optional Front-Wheel Power Assist.
The dual control stations (right and left-side) are each equipped with an operator’s seat,
steering wheel and direction/speed control console.
Engine Tachometer/Hour Meter
The engine Tachometer/Hour Meter (4, Figure 3-2) registers the engine RPM and the total
number of hours the engine has operated. It does not continue to accumulate time when the
main power is ON and the engine is not running.
Maintenance Indicator
The Maintenance Indicator (5, Figure 3-2) illuminates when a maintenance task needs to be
performed. This is a reminder only provided for your convenience. DO NOT depend on this
indicator to inform you of maintenance requirements. It is your responsibility to perform
scheduled maintenance at the recommended intervals. Refer to Section 5, MAINTENANCE
INSTRUCTIONS.
Wait to Start Indicator
The Wait-To-Start Indicator (6, Figure 3-2) will extinguish when the glow plugs in the diesel
engine have completed their pre-heating cycle and the engine is ready to start.
3-3
Section 3
Water in Fuel Indicator
The Water In Fuel Indicator (7, Figure 3-2) illuminates when the presence of water is detected
in the fuel system.
Figure 3-2
3-4
4.
Tachometer/Hour Gauge
11.
Oil Pressure Gauge
5.
12.
Empty Tunnel Indicator
6.
Wait To Start Indicator
13.
Hydraulic Filter Indicator
7.
Water In Fuel Indicator
14.
Water Temperature Gauge
8.
Stop ENG Indicator
15.
Battery Gauge
9.
Check ENG Indicator
16.
Oil Temperature Gauge
10.
Brake Engaged Indicator
Section 3
Stop Engine Indicator
!
CAUTION
EQUIPMENT DAMAGE.
SHUT DOWN THE ENGINE IMMEDIATELY IF THE STOP ENG INDICATOR
IS ILLUMINATED.
FAILURE TO DO SO MAY RESULT IN ENGINE FAILURE RESULTING IN
LOSS OF USE AND MAJOR REPAIR COSTS.
The STOP ENG Indicator (8, Figure 3-2) illuminates when a major malfunction has been
detected regarding the engine. If this Indicator illuminates, SHUT DOWN the ENGINE
IMMEDIATELY.
Check Engine Indicator
The Check ENG Indicator (9, Figure 3-2) illuminates whenever a possible problem is detected
regarding the engine. You do not need to shut down the engine immediately, but you should
give the matter you attention as soon as possible.
Brake Engaged Indicator
The Brake Engaged Indicator (10, Figure 3-2) illuminates when the parking brake is engaged,
the Main Switch is in the ON position and there is power to the system. The Parking Brake
Light will be extinguished when the Parking Brake is disengaged or there is no electric power
present.
Oil Pressure Gauge
The gauge (11, Figure 3-2) displays the engine oil pressure. The pressure of warmed engine
oil should remain above 30 PSI at 2200 revolutions per minute (RPM).
Empty Tunnel Indicator
The Empty Tunnel Indicator is functional only if the machine is equipped with an optional
Material Level Indicator Kit. The Empty Tunnel Indicator (12, Figure 3-2) illuminates when
either of the material indicator sensors mounted on the bottom of the flow gates are no longer
contacting the paving material.
3-5
Section 3
Hydraulic Filter Light
!
CAUTION
Possible equipment damage.
When the Hydraulic Filter Indicator remains illuminated for extended
periods of time (1 hour or more), replace the hydraulic oil filter.
Failure to do so may cause premature damage to the hydraulic system or
degraded system performance.
The Hydraulic Filter Indicator (13, Figure 3-2) remains illuminated continuously when it is time
to change the hydraulic oil filter. IMPORTANT: The Hydraulic Filter Light will always illuminate
at start-up and remain illuminated until the hydraulic fluid heats to the normal operating
temperature. Normally, this takes about ten minutes. If the light remains illuminated throughout
the day, the filter is restricting the flow and should be replaced as soon as possible.
Water Temperature Gauge
The Water Temperature Gauge (14, Figure 3-2) displays the engine water temperature. The
temperature of warmed engine coolant should remain below 230° F (110° C) at all times under
normal operating conditions.
Battery Gauge
The Battery Gauge (15, Figure 3-2) displays the electrical system voltage. The reading should
remain above 10.5 Volts when the engine is operating.
The Oil Temperature Gauge (16, Figure 3-2) displays the hydraulic tank oil temperature. The
temperature of warmed hydraulic fluid should remain below 230° F (110° C) at all times under
normal operating conditions.
Front Wheel Assist Switch
NOTE: These hydrostatic drive units will operate only when the drive
motor is in the LOW position and the Direction-Speed Control Lever is in
the FORWARD position. They are non-operative in all other traction
modes, including NEUTRAL and REVERSE, even though this switch may
be in the ON position.
The Front Wheel Assist Switch (17, Figure 3-3) is a two-position switch (ON/OFF) that is used
to operate the Front Wheel Power Assist units located in the rear bogie wheels beneath the
hopper.
3-6
Section 3
Starter Button
The Starter Button (18, Figure 3-3) is used to apply power to the starter, thereby starting the
engine.
Figure 3-3
17.
Front Wheel Assist Switch
23.
L.H. Flowgate Switch
18.
Starter
24.
Screed Control Switch
19.
Engine Kill Button
25.
Auger Control Switch
20.
Transmission Shift
26.
Hopper Control Switch
21.
Motor Shift
27.
Horn
22.
R.H. Flowgate Switch
Engine Kill Button
The Engine Kill Button (19, Figure 3-3) is the master switch for all circuits on the machine. This
switch must be closed (pulled out) to operate any of the electrically controlled functions. It may
be “hit” (pushed in) to kill all functions. This switch should be opened (pushed in) when the
machine is parked or unattended.
Transmission Shift Switch
The Transmission Shift Switch (20, Figure 3-3) is used to shift the 2-speed transmission units
in each final drive between HIGH and LOW. This switch is spring captured in detent positions
to remain in the selected position and resist accidental bumping. The switch must be pulled
out to move between the LOW and HIGH positions.
3-7
Section 3
Motor Shift Switch
NOTE: Shifting “on-the-go” allows for changing from 1) Low Pave to 2)
High Pave. It also allows for changing from 3) Low Travel to 4) High Travel
without requiring a stop.
The Motor Shift Switch (21, Figure 3-3) is used to shift the 2-speed traction-drive motors in
each final drive between HIGH and LOW. Shifting the traction-drive motor while the machine
is moving is provided by changing the displacement of the motors.
RH Flowgate Control Switch
The RH Flowgate Control Switch (22, Figure 3-3) is an OPTION. Not all machines are
equipped with this switch. It is used to electrically adjust the right-hand opening in the
respective conveyor tunnel to increase or decrease the volume of paving material being
delivered to the augers.
LH Flowgate Control Switch
The LH Flowgate Control Switch (23, Figure 3-3) is an OPTION. Not all machines are
equipped with this switch. It is used to electrically adjust the left-hand opening in the respective
conveyor tunnel to increase or decrease the volume of paving material being delivered to the
augers.
Screed Control Switch
This Screed Control Switch (24, Figure 3-3) controls the vertical position of the screed. Push
the switch to the UP position to raise the screed for transport. The spring-centered switch will
return to the HOLD position when released indicating the screed is retained by the hydraulics
in whatever position it stops. Push the switch to the DOWN position to allow the screed to
lower. Leave the switch in the HOLD position to allow the screed to freely float on the paving
material, unrestricted by the hydraulics.
Auger Control Switch
NOTE: Auger Override switches located on the Screed Control Boxes
take priority on the Control Console Switches in all positions.
The Auger Control Switch (25, Figure 3-3) controls the vertical position of the augers varying
grade clearance from 114 mm (4 1/2-inches) to 260 mm (10 1/4-inches). Push the Auger
Control Switch to the UP position to raise augers and to the DOWN position to lower them.
The spring-centered HOLD position indicates the auger is retained by hydraulics in whatever
position it stops.
In the detent AUTO position, the eruptive auger/conveyor will operate according to signals
originating from the Feed Control Sensors and only when the Direction-Speed Lever is in the
FORWARD position.
3-8
Section 3
Hopper Control Switch
The Hopper Control Switch (26, Figure 3-3) controls the hopper wings. Push it to the Up
position to fold the wings in and feed paving materials into the conveyors. Push it to the DOWN
position to fold the wings out for loading of the hopper. The spring-centered position indicates
that the hopper wings are retained by the hydraulics in whatever position they stop.
Horn Button
The Horn Button (27, Figure 3-3) is used to sound the horn.
RH and LH Conveyor Switches
The RH (right hand) and LH (left hand) Conveyor Switches (28, Figure 3-4) activate the Auger/
Conveyor Systems on the indicated side of the machine. In the OFF position, the respective
auger/conveyor will not operate. In the MANUAL position, the respective auger/conveyor will
operate full time at the maximum speed which has been set on the Auger Speed Dial located
on the respective Screed Control Box until switched to OFF or AUTO. In the AUTO position
the conveyors are cycled on and off automatically via commands from either the ultrasonic
sensor or paddle sensors that are part of the Automatic Feed Control system described in
Section 1 of this manual.
Figure 3-4
33.
Positive Traction Switch
28.
Left-Hand and Right-Hand Conveyor Switches
29.
Parking Brake Switch
34.
Pivot Steer Switch
30.
Screed Vibrator Switch
35.
Truck Hitch Button
31.
Governor Switch
36.
Ventilation Control Switch
32.
Throttle Switch
3-9
Section 3
Parking Brake Switch
The Parking Brake Switch (29, Figure 3-4) activates the parking brake when switched to the
ON position. The parking brake is always automatically engaged if the machine has a total
electrical failure or the Main Power/Engine Kill Switch is “hit”. The parking brake will also
automatically engage if there is a sudden drop in general purpose hydraulic pressure. These
emergency conditions override all other settings and engage the parking brake regardless of
the switch position.
Screed Vibrator Switch
The Screed Vibrator Switch (30, Figure 3-4) activates the operation of the screed vibrators in
three positions: AUTO, OFF and MANUAL. In the OFF position, the vibrators will not operate.
In the MAN position, the vibrators will operate full time until turned OFF or AUTO. In the AUTO
position, the vibrators will operate only when the Direction-Speed Lever (2, Figure 3-1) is
moved FORWARD.
Governor Switch
The Governor Switch (31, Figure 3-4) controls the maximum engine RPM at full throttle. When
the control is set to PAVE, the maximum engine RPM is limited to 1800 RPM. When the switch
is set to TRAVEL, the maximum engine RPM is increased to 2200 RPM.
Throttle Switch
The Throttle Switch (32, Figure 3-4) is a three-position selector for engine throttle speed. The
engine will IDLE in the center position at 1000 RPM. When the switch is moved to the FULL
position, the engine runs at 2200 RPM. When the switch is moved to the AUTO position, the
engine will idle when the Direction-Speed Levers (2, Figure 3-1) are in the NEUTRAL position
and the governed RPM will increase automatically when the levers are moved FORWARD and
REVERSE.
Positive Traction Switch
NOTE: Positive traction is intended for limited use. It should only be
turned ON when paving on loose bases or slippery surfaces. It should be
turned OFF in tight steering situations (i.e., when paving cul-de-sacs or
pivot steering).
The Positive Traction Switch (33, Figure 3-4) is a two-position switch (ON/OFF) used to turn
the positive traction features on or off and prevent loss of traction effort when paving by
producing limited slip between the Positive traction drive units.
3-10
Section 3
Pivot Steer Switch
The Pivot Steer Switch (34, Figure 3-4) is used to produce tighter turns than can be
accomplished by normal steering. When the switch is pushed LEFT or RIGHT, the respective
traction pump is stroked to neutral producing hydrostatic braking to the inside drive wheel. The
opposite drive wheel continues to turn, causing the front end to skid in the chosen direction.
While in the pivot steer mode, the inside tire is not locked in position and may rotate a little as
the machine turns. This is a normal operating condition.
Truck Hitch In/Out Button
The Truck Hitch In/Out Button (35, Figure 3-4) is an OPTION. Not all machines are equipped
with this switch. Push this button to the IN position to retract the Truck Hitch. Push this button
to the OUT position to open the Truck Hitch. The spring-centered position indicates that the
hitch is retained by the hydraulics in whatever position it stops.
Ventilation Control Switch
The ventilation control switch (36, Figure 3-4) located on the Operator’s Swing Console,
controls the operation of the SmokEater® Ventilation Control System. Push the switch to the
closed position to turn the system fan on. In this position the fan will remain on until the switch
is in the center, OFF position or in AUTO. Push the switch down to put it in the AUTO position.
In the AUTO position the fan will activate whenever the Direction-Speed Lever is not in
NEUTRAL.
Brake Release Hand Valve
The brake release hand valve (38, Figure 3-5) is located beneath the deck and is used to
obtain freewheeling of the machine by applying hydraulic pressure to the brake packs within
the final drive planetaries. Brakes can only be manually released by applying at least 400 PSI
hydraulic pressure using the Hand Pump (37, Figure 3-5) Also see page for Towing
instructions.
!
WARNING
Personal Injury Hazard.
Do not close the brake release valve except to release the brakes for
emergency towing. The machine can roll when the secondary/parking
brakes are released.
Failure to adhere to this admonishment may result in property damage,
serious injury or even death.
3-11
Section 3
Brake Release Hand Pump
The brake release hand pump (37, Figure 3-5) is used to manually unlock the brake packs
within the final torque hubs by applying at least 400 PSI hydraulic pressure. 25 to 30 strokes
are normally required to reach 400 PSI.
Figure 3-5
Material Indicator (Option)
The material indicator sensors are an option. Not all machines are equipped with the material
indicator sensors and lights. The material indicator system consist of sensors (39, Figure 3-6)
which are installed on the bottom of each of the flow gates. These sensors are connected to
a flashing light (Empty Tunnel Indicator, Item to inform the operator when material flow
becomes inadequate. They operate similar to the feed control paddles installed near the ends
of the augers to control the material feed. The sensors do not directly control the ON-OFF
function of the feed system. That judgement is left to the operator.
Figure 3-6
3-12
Section 3
Flow Gate Position Indicators
The Flow Gate Position Indicators (40, Figure 3-7) provide the operator with a means of
determining the position of the flow gates (39, Figure 3-6) from the operators seat. This is
useful as the operator adjusts the flow gates from the main console.
Figure 3-7
Rear Control Stations
The paver/finisher is equipped with two rear control panels (left and right side) used to help
control the grade and slope of the screed during paving. Refer to Figure 3-8 for a view of this
control station. Note that if your vehicle is equipped with the optional Blaw-Kontrol II, the
control panel arrangement will resemble that shown in Figure 3-9, rather than that shown in
Figure 3-8. The controls described in this paragraph, however, are applicable to both
configurations.
Figure 3-8
41
Jog Toggle Switch
42
Up/Down Indicators
43
3-Position Function Toggle Switch
3-13
Section 3
Jog Toggle Switch
The Jog Toggle Switch (41, Figure 3-8) is operational only when the 3-position function toggle
switch (43, Figure 3-8) is in the MANUAL position. When operational this switch is connected
directly to the respective (right-hand side or left-hand side) control valve.
Up/Down Indicators
The UP/DOWN Indicators (42, Figure 3-8) provide an indication of the output signal of the
respective grade or slope controllers.
3-Position Function Toggle Switch
The 3-position function toggle switch (43, Figure 3-8) selects the type of operation. This
selection is either MANUAL, MONITOR or AUTOMATIC.
When set to the MANUAL position, the jog toggle switch (41, Figure 3-8) is connected directly
to either the right-hand or left-hand (respectively) control valve. The UP and DOWN Indicators
(42, Figure 3-8) do not flash; they simply indicate the output signal of the grade sensor or slope
controller (Figure 3-9).
When set to the MONITOR position, the control valve is not connected to the jog switch and
the UP and DOWN Indicator lights (42, Figure 3-8) provide an indication of the output signal
of the respective grade or slope controllers (Figure 3-9).
When set to the AUTOMATIC position, the solenoid valve is connected directly to the Grade/
Slope controller (Figure 3-9). In this instance, the UP and DOWN Indicators (42, Figure 3-8)
not only provide an indication of the output signal of the Grade/Slope controllers, but also
indicate the current tow point cylinder action.
3-14
Section 3
Slope/Grade Controller
Two optional panels (left and right side) are provided to accurately set slope and grade of the
mat. Refer to Figure 3-9 for a view of the slope/grade controller and a list of each control
contained on that panel. Note that the slope/grade control panel mounts directly above a
standard rear control station (Figure 3-8) also pictured below for clarity. Keep in mind that the
switch/indicator descriptions provided for the control station (Figure 3-8) are applicable with or
without the installation of the slope/grade controller.
Figure 3-9
44.
Mode Switch
45.
Warning Indicator
46.
LCD
47.
Up/Down Knob
48.
Selector Switch
Mode Switch
The Mode Switch (44, Figure 3-9) selects the type of operation, SLOPE LEFT, GRADE or
SLOPE RIGHT. The center position of this switch selects GRADE, while the left or right
position selects the respective slope function.
3-15
Section 3
Warning Indicator
The Mode Switch (44, Figure 3-9) selects the type of operation, SLOPE LEFT, GRADE or
SLOPE RIGHT. The center position of this switch selects GRADE, while the left or right
position selects the respective slope function.
Warning Indicator
The Warning Indicator (45, Figure 3-9) illuminates when the automatic diagnostics have
detected a malfunction. At the same time an error code will appear in the LCD (46, Figure 39) that can be used to aid in fault isolation. These error codes are addressed in Section 6,
TROUBLESHOOTING.
LCD
The Liquid Crystal Display (LCD) (46, Figure 3-9) provides the operator with a wide range of
operational information.
Up/Down Knob
The UP/DOWN Knob (47, Figure 3-9) is used to control mat depth on the grade side of the
machine and maintain/change the slope as required on the opposite side of the machine.
Selector Switch
The Selector Switch (48, Figure 3-9) directs output from the potentiometer to maintain or alter
either the grade, the slope or the LCD (46, Figure 3-9) depending on the mode.
Screed Control Panels
Screed control panels are mounted at each rear corner of the paver/finisher. There is a lefthand (LH) and right-hand (RH) control panel. These panels enable the operator to control the
screed from the rear of the machine. Refer to Figure 3-10 and Figure 3-11 for pictures and
explanations of each control panel. Even though these panels are almost identical mirror
images of one another, separate Figures have been provided for clarity.
3-16
Section 3
LH Control Panel
Refer to Figure 3-10 for a view of the LH control panel and a brief explanation of the panel
controls. This control panel enables the operator to control the screed from a convenient
location.
Figure 3-10
49.
Extension Slope Toggle Switch
54.
Extension Fuel Pump Power Switch
50.
LH and RH Flowgate Control
Toggle Switches
55.
Main Fuel Pump Power Switch
51.
Auger Override Toggle Switch
56.
Main Igniter Power Switch
52.
Auger Extension Switch
57.
Auger Speed Control Knob
53.
Extension Heater Ignition Switch
58.
Screed Extension In/Out Toggle Switch
The Extension Slope Toggle Switch (49, Figure 3-10) is used to establish the slope of the
respective (LH and RH) primary extendible section in relation to the main screed.Pushing to
the down arrow position causes the outer end of the primary extendible section to lower, while
pushing the switch to the up arrow position will cause it to raise.
LH and RH Flow Gate Control Toggle Switches
These switches (50, Figure 3-10) operate the adjustable flow gates that meter material
delivery to the augers on the respective LH and RH side of the machine. Moving a switch
upward raises the respective gate, while moving the switch downward lowers the gate. While
the switch is in the center position, the gate will remain stationary. These Flow Gate Control
Toggle Switches are unique to the LH Control Panel and are one of the few switches that are
not shared between the two panels.
3-17
Section 3
The Auger Override Toggle Switch (51, Figure 3-10) allows the operator to take local control
of the auger. When this switch is in the OFF position, control of the auger/conveyor system
remains with the feed control sensors. When the switch is moved to the left or right position,
local control of the respective auger/conveyor system is transferred to this control panel.
The Auger Extension Switch (52, Figure 3-10) enables the operator to locally move the auger
extensions. Pressing this switch will cause the auger extensions to operate under local control.
Extension Heater Igniter Switch
The Extension Heater Ignition Switch (53, Figure 3-10) when used in conjunction with the
Extension Fuel Pump Switch (54, Figure 3-10) allows the operator to operate the heater for
the screed extensions.
Extension Fuel Pump Switch
The Extension Fuel Pump Switch (54, Figure 3-10) when used in conjunction with the
Extension Heater Igniter Switch (53, Figure 3-10) allows the operator to operate the heater for
The Main Fuel Pump Power Switch (55, Figure 3-10) operates the fuel pump for the main
screed heater. Note that this switch must be in the ON position in order for the Extension Fuel
Pump Switch (54, Figure 3-10) to become operative.
The Main Igniter Power Switch (56, Figure 3-10) allows ignition of the main screed heaters.
Note that this switch must be in the ON position in order for the Extension Heater Igniter Switch
(53, Figure 3-10) to become operative.
The Auger Speed Control Knob (57, Figure 3-10) becomes active when the Auger Override
Toggle Switch (51, Figure 3-10) has been engaged. Otherwise, this control is inoperative.
When operating, this knob provides a variable range auger/conveyor system speed control.
Clockwise rotation increases the speed of the auger/conveyor system, while counterclockwise
rotation slows the speed of the system.
3-18
Section 3
The Screed Extension IN/OUT Toggle Switch (58, Figure 3-10) allows the operator to change
the position of the screed extensions. Pressing the toggle switch to the IN position will retract
the screed extensions. Pressing the toggle switch to the OUT position will extend the screed
extensions. When the switch is in it’s center position the screed extensions will remain in their
established positions.
RH Control Panel
Refer to Figure 3-11 for a view of the RH control panel and a brief explanation of the panel
controls. This control panel enables the operator to control the screed from a convenient
location.
Figure 3-11
59.
64.
60.
65.
61.
66.
62.
67.
63.
Fuel Pump Switch
68.
The Extension Fuel Pump Switch (59, Figure 3-11) when used in conjunction with the
Extension Heater Igniter Switch (60, Figure 3-11) allows the operator to operate the heater for
3-19
Section 3
The Extension Heater Igniter Switch (60, Figure 3-11) when used in conjunction with the
Extension Fuel Pump Switch (59, Figure 3-11) allows the operator to operate the heater for
The Auger Override Toggle Switch (61, Figure 3-11) allows the operator to take local control
of the auger. When this switch is in the OFF position, control of the auger/conveyor system
remains with the feed control sensors. When the switch is moved to the left or right position,
local control of the respective auger/conveyor system is transferred to this control panel.
The Auger Extension Switch (62, Figure 3-11) enables the operator to locally move the auger
extensions. Pressing this switch will cause the auger extensions to operate under local control.
Fuel Pump Switch
The Fuel Pump Switch (63, Figure 3-11) operates the fuel pump that provides fuel to all
heaters (both main and extensions). This switch must be in the ON position to energize the
fuel pump for the screed heaters to operate. The Fuel Pump Switch is unique to the RH Control
Panel and is one of the few that are not shared between the two panels.
The Extension Slope Toggle Switch (64. Figure 3-11) is used to establish the slope of the
respective (LH and RH) primary extendible section in relation to the main screed. Pushing to
the down arrow position causes the outer end of the primary extendible section to lower, while
pushing the switch to the up arrow position will cause it to raise.
The Screed Extension IN/OUT Toggle Switch (65, Figure 3-11) allows the operator to change
the position of the screed extensions. Pressing the toggle switch to the IN position will retract
the screed extensions. Pressing the toggle switch to the OUT position will extend the screed
extensions. When the switch is in it’s center position the screed extensions will remain in their
established positions.
This Auger Speed Control Knob (66, Figure 3-11) becomes active when the Auger Override
Toggle Switch (61, Figure 3-11) has been engaged. Otherwise, this control is inoperative.
When operating this knob provides a variable range auger/conveyor system speed control.
Clockwise rotation increases speed of the auger/conveyor system, while counterclockwise
rotation slows the speed of the system.
3-20
Section 3
The Main Igniter Power Switch (67, Figure 3-11) allows ignition of the main screed heaters.
Note that this switch must be is in the ON position in order for the Extension Heater Igniter
Switch (60, Figure 3-11) to become operative.
The Main Fuel Pump Power Switch (68, Figure 3-11) operates the fuel pump for the main
screed heater. Note that this switch must be in the ON position in order for the Extension Fuel
Pump Switch (59, Figure 3-11) to become operative.
3-21
Section 3
3-22
OPERATING CONTROLS AND INSTRU-
SECTION 4 - OPERATING
INSTRUCTIONS
4-1
Section 4
GENERAL
This section contains general operating guidelines for the PF-161 Paver/Finisher. These
guidelines are presented in a high-level topically general manner since it is impossible to
predict your exact operating parameters.
This section contains the following topics:
•
Pre-start checks and verifications
•
Starting the machine
•
Operating the machine
•
Moving the machine between worksites
•
Loading the machine under its own power for transport
•
Securing the machine to the transporter
•
Towing the machine
Pre-Start Checks and Verifications
Before starting the PF-161 Paver/Finisher, the machine should be inspected to verify that each
is in good operating condition using the following checklist as a guide:
1. Check fuel level in the fuel tank
2. Engine lubricating oil at the proper level
3. Engine coolant in the coolant recovery bottle at the proper level
4. Hydraulic reservoir fluid at the proper level
5. Machine lubricated in accordance with the instructions in this manual
6. No visible signs of equipment damage
7. Check parking brake on flat open ground. Low speed range (Low Motor Shift
Switch position) should not overpower brake. If parking brake can be
overpowered, brake packs inside of final drive planetaries must be repaired.
Parking brake is not adjustable.
8. Front-wheel-assist relief pressure should be set according to operating surface.
Also check the following items periodically or where applicable, refer to the
Section 5, MAINTENANCE INSTRUCTIONS of this manual.
9. Planetary fluid is present at the proper level
10. Engine fuel and air filters. Engine properly tuned and operating smoothly.
Tension in the Fan Belt has been properly adjusted so that the Fan Belt is tight.
11. Sufficient hydraulic pressure
4-2
Section 4
12. Conveyors adjusted properly and wear checked. Refer to Section 5,
MAINTENANCE INSTRUCTIONS of this manual.
13. Auger/Conveyor drive chains adjusted properly and auger wear checked. Refer
to the Section 5, MAINTENANCE INSTRUCTIONS of this manual.
14. Drive tires properly inflated (35 ±5 psi).
15. Inspect screed for excessive wear.
16. Inspect screed heaters and gas lines for serviceability.
17. Check for excessive play in crown jack and their mountings.
18. Check for smooth operation of the mat thickness adjusting screws.
Starting the Machine
The following are general guidelines to be adhered to when starting up the machine. These
guidelines are divided into several categories. Below is a list of these general startup
categories followed by the guidelines for each.
•
Suggestions to make cleanup easier
•
Positioning the machine and its controls
•
Initial screed elevation
•
Initial screed angle-of-attack
•
Lighting the screed heater
•
Positioning of material truck and starting to pave
Suggestions to Make Cleanup Easier
!
WARNING
Fire Hazard
Never use the wash-down spray while the screed heaters are operating.
The wash down spay is fuel and could ignite.
Failure to adhere to this warning may cause serious injury or even death.
4-3
Section 4
Just prior to starting to lay bituminous base materials, apply Blaw-Kote® Lubricant Shield, or
use the machine’s wash down hose to wet all surfaces with fuel oil which will come in contact
with paving material to prevent paving material from adhering to the mechanical components
of the paver/finisher. These surfaces typically are:
•
Push rollers
•
Hopper
•
Conveyors
•
Augers
•
Screed face and bottom
•
Screed extensions
•
Edger plates
Positioning the Machine and its Controls
Keep the following criteria in mind when initially positioning the machine for a job:
•
Position the machine on the joint or point from which the paving is to start.
•
Screed extensions should be appropriately adjusted if the job requires their use.
•
Feed control sensors should be installed.
•
Choose the operator’s position (left-hand or right-hand) which provides maximum
visibility in relation to a steering reference and/or obstacles on the job.
•
Position the steering guide in relation to the steering reference (if it is to be used).
•
If the Automatic Level Control (Joint Matcher) option attachment is to be used, make
certain that it is set up and operating properly.
•
Initially set flow gates as recommended. Final precise adjustment is made after
paving has started and material demand on each side of the screed versus supply is
observed.
Initial Screed Elevation
When starting to lay a bituminous mat, it is essential that the bottom of the screed be elevated
from the grade a distance equal to the desired mat depth plus enough extra height to allow for
mat compaction by rolling. This is normally accomplished by placing wood starting blocks of
the required thickness under each end of the screed. Example: If a finished mat of 51 mm (2in.) is to be laid, starting blocks 65 mm (2.5 in.) thick would provide a suitable starting height.
Note that starting to pave from the end of a previously laid mat, starting blocks with a thickness
only to the amount of compaction are all that is required (14 mm(0.5-in.)) with reference to the
foregoing example. When initially setting up the screed elevation, keep the following
guidelines in mind:
•
4-4
Starting blocks should be as long, or longer, than the dimension of the screed plate
(front to rear).
Section 4
•
Starting blocks should be placed longitudinally with the paver’s direction of travel,
one under and near each end of the screed.
•
Starting block placement will provide the screed plate with a full bearing parallel
surface under each end that is essentially parallel with the grade and on which the
screed can be nulled out.
•
After the screed is on the blocks, it must be nulled out. Nulling out the screed is an
expression used to describe adjusting both ends of the screed so that the screed
plate rests absolutely flat on the starting blocks. The screed will be nulled when the
following conditions are satisfied.
— Both front and rear edges of the screed rest squarely on the starting blocks.
— Screed depth cranks have a limited amount of free rotary movement between
screed tension in either direction. The presence of this limited free rotary
movement is an indication that the screed is nulled out.
Initial Screed Angle-of-Attack
At this point, the screed angle-of -attack should be introduced. The weight of the screed exerts
a compacting force as it passes over the bituminous mix. The angle-of-attack is an adjustment
which raises the front edge of the screed causing the screed to climb enough to equal the
amount of compaction that it exerts on the mix. Exact angle-of-attack is always an unknown
factor since many factors, such as variation in the mix, composition, temperature and paving
speed, all affect the amount of angle-of-attack required. However, it is known that there will be
compaction by the screed making it necessary to introduce some angle-of-attack before the
screed leaves the starting blocks.
With the screed properly nulled out, introduce a start-up angle-of-attack by turning both screed
depth cranks one full turn counterclockwise (CCW).
When paving begins, check the mat depth and adjust the depth cranks until desired mat depth
is obtained.
Lighting the Screed Heater
!
WARNING
Fire Hazard
Never fuel the machine while the screed heaters are operating.
Never use the wash down system while the screed heaters are operating.
Never attempt to relight the screed heaters for any reason until you are
absolutely sure excess fuel has been removed from the burner interior
and surrounding areas.
Failure to observe this admonishment in its entirety may result in
property damage, severe personal injury or even death.
4-5
Section 4
!
CAUTION
The burners are intended for use during initial heating of the screed plate.
During paving the material itself will keep the screed plate hot. Avoid
overheating of the screed.
Failure to adhere to this admonishment could result in equipment
damage including warping of the screed plate and frame.
Before starting to pave with bituminous materials, the screed should be preheated. This helps
to prevent the hot mix from sticking to a cold screed plate and encourages the production of a
smooth tight mat. If the machine sits idle for a long period of time between loads, the screed
should be pre-heated again. Allow 12-to-15 minutes for preheating a cold screed. Five-to-eight
minutes will be sufficient when the screed has been sitting on warm material.
NOTE: The heater circuit contains a timer switch which shuts off the fuel
pump after a factory set period. This is to prevent overheating which
could warp the screed plate. To reset this timer, cycle the fuel pump
switch OFF then ON.
Light the screed heaters and preheat the screed as follows:
NOTE: The below procedure addresses both the main and extension
burners. If your vehicle does not use a screed extension, ignore the
operation of the extension screed burner controls mentioned in the below
procedure.
1. Check each of the fuel valve switches (68 and 59, Figure 4-1) (main and
extension) to be sure they are in the DOWN or in the OFF position.
2. Turn on the Fuel Pump (63, Figure 4-1), the Main Blower (67, Figure 4-1), and
extension blower switches (60, Figure 4-1) ON and allow them to operate for
one minute to purge the system before lighting the burners.
4-6
Section 4
3. Turn both Burner Blower switches (67 and 60, Figure 4-1) OFF.
Figure 4-1
4. Ignite the screed heaters one at a time as follows:
•
If your screed uses a glow plug ignition, perform the following:
— Run the paver engine at FULL RPM.
— Hold the MAIN and EXTENSION Burner Switches (67 and 60, Figure 4-1) to
IGNITER for 20 seconds.
— Flip the FUEL Toggle Valves (68 and 59, Figure 4-1) to the Up or set to the On
position to ignite the burners and to continue operating the respective screed
heater.
— Push the MAIN and EXTENSION Burner Switches (67 and 60, Figure 4-1) to
BLOWER as soon as ignition takes place.
•
If your screed uses a spark type ignition, perform the following:
— Press the MAIN and EXTENSION Burner Switches (67 and 60, Figure 4-1) to
IGNITER (produces an arc between two electrodes)
— Flip the FUEL Toggle Valves (68 and 59, Figure 4-1) to the up or press to the on
position to ignite and continue operating the respective screed heater.
— Switch the MAIN and EXTENSION Burner Switches (67 and 60, Figure 4-1) to
BLOWER as soon as ignition takes place.
5. Adjust baffles on each burner unit, as required, to obtain maximum heat and
clean burning flames inside of the burner chambers. Listen for a maximum roar
and watch for minimum smoke as an indication of optimum combustion.
6. Run the vibrators while heating the screed.
7. Re-grease the vibrator drive shaft and U-joint bearings immediately after
heating the screed.
4-7
Section 4
8. When the screed reaches operating temperature and the burners are no longer
required, shut the burners down as follows:
•
Turn the FUEL PUMP Switch (63, Figure 4-1) OFF.
•
Turn the MAIN and EXTENSION FUEL Valves (68 and 59, Figure 4-1) OFF.
•
Wait 5 minutes (allowing blowers to run).
•
Position the MAIN and EXTENSION Burner Switches (67 and 60, Figure 4-1) to
the OFF position.
Positioning the Material Truck and Starting to Pave
The following is a guideline to aid in the initial placement of the material track in front of the
PF-161 Paver/Finisher. It provides information regarding placement of the truck and the initial
control setting for the machine to begin to receive material.
1. Position a truck loaded with paving material against the push rollers in front of
the paver (1, Figure 4-2).
Figure 4-2
4-8
Section 4
2. Set the throttle switch (32, Figure 4-3) on the main control panel to the AUTO
(UP) position.
Figure 4-3
3. Set the L.H. and R.H. Conveyor Switches (28, Figure 4-3) to the AUTO (LEFT)
position.
4. Fill the hopper and allow the conveyors to automatically shutdown as the
augers become full.
5. Set the Screed Vibrator Switch (30, Figure 4-3) to the AUTO (LEFT) position.
6. Verify that the Motor Shift Switch (21, Figure 4-3) is in the LOW position (not
depressed).
7. Move the Direction Speed lever (3, Figure 4-4) FORWARD and begin to pave.
Figure 4-4
8. As paving progresses, make adjustments necessary to maintain adequate
material delivery and produce a satisfactory mat. Refer to the Paving Manual
for information pertaining to controlling mat quality.
4-9
Section 4
OPERATING THE MACHINE - GENERAL GUIDELINES
The following are general guidelines to be followed whenever you are operating the machine.
Read and understand these guidelines thoroughly before attempting to operate the machine.
!
WARNING
Personnel Injury, Property Damage
Do not allow untrained personnel to operate this machine. Even the
seemingly simple task of relocating the machine could be hazardous if
attempted by an untrained person.
Failure to adhere to this admonishment could result in property damage,
severe personnel injury or even death.
!
CAUTION
Equipment Damage
Make sure you have preformed all the pre-checks required and that all
equipment fluid levels are adequate.
damage, performance degradation or premature failure of mechanical
components.
1. Always sound the horn before moving the machine in either direction to alert
persons in the vicinity. Allow sufficient time for persons to move from the
vehicle’s path before putting the machine into motion. This also verifies that the
horn is operational.
2. Monitor all warning lights. If instruments or lights indicate a fault or problem,
contact appropriate personnel to identify the problem and correct it.
3. Monitor and ensure that the horn and any optional lighting are operational.
4. Always move the steering wheel slowly and monitor the steering action.
5. Always fully depress the Engine Kill switch on the main control panel and
remove the ignition key before leaving the operator station.
4-10
Section 4
MOVING THE MACHINE - UNDER PROPULSION
Follow the below guidelines whenever moving the machine under it’s own propulsion.
1. Physically walk around the paver, ensuring that no one is in the area, all
components are secure and that nothing is under or in the way of the wheels.
!
WARNING
Personnel Injury, Property Damage
Do not allow untrained personnel to operate this machine. Even the
seemingly simple task of relocating the machine could be hazardous if
attempted by an untrained person.
Failure to adhere to this admonishment could result in property damage,
severe personnel injury or even death.
!
CAUTION
Equipment Damage
Make sure you have preformed all the pre-checks required and that all
equipment fluid levels are adequate.
damage, performance degradation or premature failure of mechanical
components.
2. Mount the machine using the steps and handrail provided at the rear of the
machine. Remember to maintain three-point contact while you are climbing
onto or off of the machine.
3. Unlock and open the cover to gain access to the main control panel.
4. Get seated on the side of the machine that will offer you the most beneficial
view, taking into account the terrain and obstacles in your area.
5. Position the main control panel in a suitable position for the side of the machine
you are seated.
6. Position the Direction Speed control lever (3, Figure 4-4) to the NEUTRAL
(centered) position.
7. Place all control switches on the main control panel to the OFF or centered
position.
4-11
Section 4
8. Position the THROTTLE Switch (32, Figure 4-5) to the IDLE (center) position.
Figure 4-5
9. Position the TRANSMISSION SHIFT Switch (20, Figure 4-5) to the LOW
position.
10. Position the MOTOR SHIFT Switch (21, Figure 4-5) to the LOW position.
11. At the Direction/Speed Control Lever (3, Figure 4-4) to be used, rotate the
hinged lockout plate out of the way, so that the lever is free to move into the
reverse range.
12. Pull the Engine Kill Button (19, Figure 4-5) all the way out.
13. Depress the STARTER Button (18, Figure 4-5). The engine should start and
come up to speed. Note that the engine will NOT START if the Direction/Speed
Control Lever is not in the NEUTRAL position.
14. Wait approximately three minutes for the engine to warm up.
4-12
Section 4
15. Raise the screed to a position above the ground using the Screed Control
switch (24, Figure 4-5). Make sure the screed cylinders are retracted
sufficiently to engage the locking support brackets (1, Figure 4-6).
Figure 4-6
16. Return the SCREED Control Switch (24, Figure 4-5) to the HOLD (center)
position.
17. Manually secure the screed in it’s elevated position by engaging the locking
support brackets (1, Figure 4-6) on the left-hand and right-hand screed
cylinders.
18. Move the machine by moving the Direction/Speed Control Lever (3, Figure 44) in the FORWARD or REVERSE direction, as needed. Note that the further
the Direction/Speed Control Lever is moved from NEUTRAL, the greater the
machine velocity will be.
19. To stop the machine, bring the Direction/Speed Control Lever back to the
NEUTRAL position.
4-13
Section 4
20. If you are moving the machine over a distance that would make a higher
velocity desirable, keep the following facts in mind:
•
The Engine GOVERNOR Switch (31, Figure 4-7) controls maximum engine RPM
at full throttle. Pave is 1800 RPM, while Travel is 2200 RPM.
Figure 4-7
•
The THROTTLE Switch (32, Figure 4-7) is a three-position switch used to select
engine throttle speeds. The center position is IDLE (1000 RPM), UP is the AUTO
position which allows for engine speed to be governed by load and transmission
settings, while the lower position is MANUAL which means the governor has
engine speed control totally.
•
The MOTOR SHIFT Switch (21, Figure 4-7) is a push-button. This switch controls
the 2-speed traction drive motors in each final drive between HIGH and LOW.
Extended is in the LOW setting while depressed is the HIGH setting. It is not
necessary to stop the machine before shifting the traction drive motors between
HIGH and LOW.
!
CAUTION
Possible Transmission Damage.
Never switch the transmission when the machine is moving.
Failure to adhere to this Caution may result in damage to the
transmission.
4-14
Section 4
•
The TRANSMISSION SHIFT Switch (20, Figure 4-7) is used to shift the twospeed transmission units in each final drive between HIGH and LOW.
•
Various combinations of these switch positions will allow for various travel/paving
speeds. Below is a list of such speeds:
•
Low Motor/Low Transmission
- 0-36 m/min (0-119 fpm) @ 2100 rpm
•
High Motor/Low Transmission
- 0-94 m/min (0-312 fpm) @ 2100 rpm
•
Low Motor/High Transmission
- 0-7.6 km/hr (0-4.7 mph) @ 2100 rpm
•
High Motor/High Transmission
- 0-19.9 km/hr (0-12.7 mph) @ 2100 rpm
•
Reverse
- Full reverse in any of the four speed ranges
MOVING THE MACHINE BETWEEN WORKSITES
Before driving the machine on public roads, check with your supervisor for instructions and
information in respect to traffic regulations regarding construction machinery.
NOTE: For more information on transporting, refer to Section 1, SAFETY
Precautions and Guidelines.
1. Clean the paver/finisher. Refer to the procedures outlined in the Maintenance
Section of this manual. Make sure it is free of debris that could become a
hazard to other vehicles as it is being moved.
2. Choose level ground which will solidly support the vehicle.
3. Clean the trailer and loading ramps.
4. Chock the wheels of the trailer before attempting to load the machine.
5. Approach the transporter loading ramp squarely to make sure the paver/
finisher does not drop off the side of the ramp.
6. Drive the paver/finisher onto the transporter.
7. Shut the engine off, remove the keys and lock all lockable compartments.
8. Apply the necessary road warnings to the machine. You will need to enlist the
help of a qualified signalman to accomplish this task.
Securing the Machine to the Transporter (Tiedown)
1. Chock all wheels.
2. Tie down machine using a chain and tensioning device or other appropriate
equipment to tie-down points.
3. Make sure the driver of the transport is aware of the paver/finisher’s total
weight, load on the axles and overall machine dimensions.
4-15
Section 4
TOWING THE MACHINE
!
CAUTION
Equipment Damage
Never highway tow the paver/finisher with the drive wheels on the
ground.
Failure to adhere to this admonishment will result in destruction of the
final drive planetary.
These towing instructions are intended to provide information pertaining to moving a disabled
paver/finisher under emergency circumstances a short distance only (off the job site, etc.)
to a transport vehicle. Towing speeds shall never exceed 1.6 kph (1 mph) under any
circumstances.
The paver/finisher can be moved even if the hydraulic system does not have enough pressure
to disengage the parking brake by using the manual hand pump and brake release valve
described in the procedure below. Never attempt to release the parking brake except under
these emergency conditions.
Perform the procedure outlined below to tow the paver/finisher.
!
CAUTION
Property Damage
Never use a flexible towing device, such as a chain, cable or straps.
Failure to adhere to this admonishment could result in a collision
between the paver/finisher and the towing vehicle causing damage to
both vehicles.
1. Attach a properly sized tow bar to the paver/finisher and an appropriate towing
vehicle.
2. Engage the brakes on the towing vehicle so that it does not begin to roll when
the paver/finisher’s brakes are released.
4-16
Section 4
3. At the Main control panel, fully depress the Engine Kill button (19, Figure 4-8).
Figure 4-8
4. Remove the left deck plate and gain access to the hydraulic hand pump
(1, Figure 4-9) and the brake release valve (2, Figure 4-9).
Figure 4-9
4-17
Section 4
!
WARNING
Personnel and Property Hazard
Never close the brake release valve, except to release the brakes for
emergency towing.
The brakes cannot be reapplied from the operator’s station once they
have been released.
Failure to adhere to this admonishment may result in the paver/finisher
free-rolling out of control causing property damage and possibly
inflicting serious injury or even causing death.
5. Close the brake release valve (2, Figure 4-9) by pushing it down and holding it
in place.
6. While holding the brake-release valve down, use the hand pump (1, Figure 49) to release the brakes. The brakes will become fully released when the
hydraulic pressure reaches 400 psi. This normally requires 35-to-40 full
strokes.
7. After the paver/finisher has been towed to the desired location, perform the
following:
4-18
•
Place chocks under each wheel.
•
Open the brake release valve by pulling it up.
SECTION 5 - MAINTENANCE
INSTRUCTIONS
5-1
Section 5
GENERAL
This section contains general maintenance instructions for the PF-161 Paver/Finisher. These
instructions are broken down into the following categories:
•
Clean-up and Washdown
•
Periodic Maintenance
•
Off-Season Storage
NOTICE
Read and understand all instructions contained in this manual, the
engine manual and any other pertinent manuals before attempting to
service this paver/finisher. Paver/finisher adjustments and servicing
shall be performed only by qualified individuals who have been properly
trained and are authorized to do so.
!
WARNING
Equipment Damage/Personnel Injury
Always mount and dismount the paver/finisher from the rear using
walkways, steps and handrails provided.
Failure to observe this admonishment could result in equipment damage
or bodily injury.
5-2
Section 5
!
WARNING
Personnel Hazard/Equipment Damage
Before attempting to service, attach or remove any part or assembly on
the paver/finisher, make certain that:
1. All controls and switches are in the OFF or centered position.
2. Hopper wings are lowered.
3. Screed is lowered or secured in the raised position.
4. Engine is shut off unless otherwise instructed.
Failure to comply with these instructions could result in equipment
damage, bodily injury or even death.
!
WARNING
Fire Hazard
Refuel the paver/finisher only when the engine in not running. DO NOT
permit sparks, open flames or smoking within 15.2 m (50 ft.) of the paver/
finisher when refueling. Never refuel paver/finisher with screed heaters
operating.
Never use the WASHDOWN system when screed heaters are operating.
Failure to comply with these guidelines could result in a fire, causing
property damage, severe bodily injury and possibly death.
5-3
Section 5
!
WARNING
Bodily Injury - Escaping hydraulic fluid under pressure can have
sufficient force to penetrate the skin causing serious personal injury. See
a doctor immediately if you are ever injured by escaping hydraulic fluid.
Serious infection or reaction can develop if proper medical treatment is
not administered immediately.
Before disconnecting a hydraulic line, be sure to relieve all pressure.
Before pressurizing a system, be sure all connections are tight and that
lines, tubes and hoses are not damaged.
Fluid escaping from a small hole can be nearly invisible. Use a piece of
cardboard or wood rather than hands to search for suspected leaks.
Failure to comply with these guidelines could result in a very serious
injury, including blindness, infection or other adverse reaction.
!
WARNING
Burn Hazard
Always open the radiator using work gloves or a heavy rag. Wear eye
protection. Turn the radiator cap slowly to the stop and allow any
pressure or steam to escape through the overflow hose.
After all pressure is removed, finish removing the cap.
Refill the radiator only when the engine is stopped or idling slowly. Pour
coolant slowly until level is 25 mm (1 in.) below the bottom of the filler
neck.
Failure to comply with these guidelines could result in severe burns, eye
injury or even blindness.
5-4
Section 5
!
WARNING
Explosion Hazard
Batteries produce explosive gases. Keep sparks and open flames away
from batteries. If a battery needs recharging, avoid sparks by turning off
the charger before making connections or disconnections.
Failure to comply with these guidelines could result in an explosion
causing severe bodily injury and even death.
!
WARNING
Chemical Hazard
Sulfuric acid in batteries is both toxic and caustic. Contact with skin will
cause severe chemical burns. Avoid all contact with skin, eyes and
clothing. When working around batteries, wear gloves, eye and face
protection.
Failure to observe these guidelines may result in severe chemical burns,
poisoning, eye injury and even blindness.
!
WARNING
Toxic Gases
Engine exhaust is toxic and potentially fatal. Before starting the engine,
be sure there is adequate ventilation. If it is necessary to operate the
vehicle inside an enclosed service area, make sure exhaust fumes are
well ventilated.
Failure to adhere to these guidelines could result in illness or physical
damage or even death.
5-5
Section 5
!
WARNING
Moving Equipment
Verify that all personnel are clear of the paver/finisher before starting so
they cannot be struck by or caught in moving parts.
Failure to adhere to this admonishment could result in bodily injury or
even death.
CLEAN UP AND WASHDOWN
This procedure shall be followed at the end of each work day while the paver/finisher is still
warm.
Keeping the paver/finisher cleaned and washed down with diesel fuel, kerosene or another
appropriate cleaning solution will ensure it’s proper performance and maximum service life.
Keeping the paver/finisher clean is an especially effective means of extending the operating
life of components in the material handling areas. Abrasive materials which accumulate in the
sprocket, bearing and auger and conveyor areas all increase stress on components and
accelerate wear.
Daily cleaning and washdown practices also promote trouble-free mat production. Cold paving
material can break loose and produce tears in the mat as they pass under the screed. All
residual asphalt materials shall be removed from the paver/finisher, especially in the material
handling areas and these surface shall be sprayed to eliminate any remaining residue. The
resulting petroleum film residue left behind after clean up and washdown reduces the potential
for material sticking the next time the paver/finisher is used.
Perform the steps outlined below to cleanup and washdown the paver/finisher.
NOTICE
Perform this procedure only in authorized/designated areas.
Performance of this procedure in areas other than those approved of by
your organization could result in serious criminal violations of
environmental regulations.
1. Drive the paver/finisher to the designated clean up and washdown area.
2. Clear the immediate area around the paver/finisher.
3. Lower hopper wings.
4. Secure screed in the raised position.
5. Position all operation switches to the OFF or centered position on the main
control panel.
5-6
Section 5
6. Fully depress the Engine Kill Button (19, Figure 5-1).
Figure 5-1
!
WARNING
Fire Hazard
Never use the WASHDOWN system when screed heaters are operating.
Failure to comply with these guidelines could result in a fire, causing
property damage, severe bodily injury and possibly death.
5-7
Section 5
7. Wait 10 minutes while the screeds cool.
!
WARNING
Fire and Personal Injury
Diesel fuel is both flammable and slippery, so extreme care must be
exercised during this clean up and washdown procedure to avoid fire and
personal injury.
Verify that the screed heaters are turned off and have cooled sufficiently.
Run the conveyors and augers only when required to gain access to all
surfaces and only after personnel are out of the material handling areas.
Never stand on augers, auger tunnels, auger guards or edger-plate
assemblies.
Never smoke or allow others to smoke while performing this procedure.
Turn the FUEL PUMP Switch on only IMMEDIATELY before you start to
use the WASHDOWN hose. Turn the FUEL PUMP Switch off
IMMEDIATELY after use of the WASHDOWN hose is completed.
Failure to adhere to these guidelines could result in falling, fire, and/or
explosion which could cause severe personal injury and even death.
8. Turn the FUEL PUMP Switch (63, Figure 5-2) on. This switch is located on the
right-hand (R.H.) screed control box.
Figure 5-2
5-8
Section 5
9. Position the WASHDOWN Hose Valve (1, Figure 5-3) to the on position. Note
that this valve is located next to the WASHDOWN Hose (2, Figure 5-3), which
is located on the R.H. side of the paver/finisher.
Figure 5-3
10. Pull the WASHDOWN Hose (2, Figure 5-3) out far enough so that the
components on the paver/finisher that need to be washed are accessible. Be
careful not to kink or damage the hose.
5-9
Section 5
11. Starting at the front of the paver/finisher and working your way back, spray
down the paver/finisher. Refer to Figure 5-4 and Figure 5-5 for diagrams of the
paver/finisher that point out areas that typically require extra attention.
Figure 5-4
12. Be sure to spray down all surfaces that come in contact with paving material,
including push-rollers, hopper surfaces, flowgates, conveyors, augers, screeds
(both main and extendible sections), edger-plates and deck areas.
13. Use a scraping device to remove accumulated material. You may need to
attach a long handle to your scraping device to reach all areas safely that
require scraping.
14. Push-rollers (1, Figure 5-4):
•
Remove all built-up material on the rollers and mounts
•
Rotate the rollers while cleaning and soak bearing ends to maintain free rotation.
!
WARNING
Personal Hazard
Do not enter hopper while engine is running. Potential for moving parts
causing severe injury is very high.
Failure to comply with this admonishment could result in serious injury.
5-10
Section 5
15. Hopper surfaces and flow gates (2 and 4, Figure 5-4):
•
Clean all hopper surfaces thoroughly.
•
Lower flow gates to clean the surfaces and raise them to gain access to the
conveyor tunnels.
Figure 5-5
!
WARNING
Do not run conveyors while using scraper to remove paving material.
Have a qualified operator at the control station at all times during this
procedure. Stand in full view of the operator while cleaning.
Never enter the hopper while the engine is running.
Never stand in the auger-trough area.
Failure to observe these guidelines could result in severe injury, loss of
limb or even death.
5-11
Section 5
16. Conveyors (3, Figure 5-4):
•
Raise hopper apron to remove material which has accumulated around the idler
shaft and front conveyor bearings.
•
Stand on the ground at a safe distance and spray moving conveyor chains and
bars.
•
Clean rear-drive sprockets and tunnel areas thoroughly.
•
Run conveyors after washdown to carry solvent into conveyor return areas under
the floor plates to help dissolve hidden asphalt.
!
WARNING
Never stand in the auger-trough area.
Never run the augers while using the scraper to remove paving material.
Have a qualified operator at the control station at all time during this
procedure. Stay in full view of the operator while cleaning.
17. Augers, auger bearings, auger tunnels and auger guards (6, Figure 5-4):
•
Clean auger surfaces thoroughly.
•
Scrape out accumulated material around bearings.
•
All material contact surfaces must be cleaned down to the metal to avoid quick
build-up when paving resumes.
18. Screed (8, Figure 5-4 and 12, Figure 5-5):
•
Face and bottom plates shall be clean and smooth on both the main and
extendible sections.
!
WARNING
Never disassemble or assemble edger-plate assemblies while augers are
running.
Failure to comply could result in severe personal injury, loss of limb or
even death.
5-12
Section 5
19. Edger-plates (7, Figure 5-4 and 11, Figure 5-5):
•
Remove and clean so they slide freely on the paver/finisher while the augers are
running.
20. Deck areas (5, Figure 5-4 and 9, Figure 5-5):
•
Remove all paving material and then, carefully remove solvent residue, so that
walking surfaces are not slippery.
PERIODIC MAINTENANCE
Periodic maintenance is typically preventative in nature and is scheduled to keep the paver/
finisher in proper operating condition. Failure to perform this maintenance at the
recommended intervals will result in unanticipated paver/finisher failure and loss of use.
All of these tasks are to be performed at a predetermined interval. Some are daily, while others
are performed weekly or even yearly. Many of these tasks involve the application of lubricants
while others are adjustments.
To perform these tasks effectively, refer to the schedule of maintenance provided later in this
section. This schedule refers to specific tasks, recommended performance intervals and
references a procedure to follow in order to perform the required tasks.
Prior to attempting to perform any task, read and understand the paragraph below regarding
lubricants. Compliance with this information is critical.
Lubricants
Use quality lubricants furnished by reliable manufacturers or as specified in Table 5-1 below.
Use the proper lubricant for each application as specified. DO NOT MIX LUBRICANTS.
!
CAUTION
Possible Equipment Damage.
Power grease guns can blow out and permanently damage bearing seals.
If power grease guns must be used, use power guns for very short bursts
of one second or less with five second delays between bursts to allow
grease to escape slowly.
Failure to observe this admonishment may result in equipment damage
and subsequent major mechanical failure.
Most bearings on the paver/finisher are permanently sealed and require no greasing. For
those bearings that do require hand greasing, the use of a hand grease gun is recommended.
Escaping grease should not be visible around the bearings or felt washers.
5-13
Section 5
Perform lubrication at the end of the day while the paver/finisher is warm. This will insure that
the lubricant reaches all critical points.
Store lubricants in clean, covered containers. Make certain that funnels, measures and all
other equipment are cleaned before and after use. Clean fittings, plug openings and other
lubrication points before servicing. Inspect and clean plugs and other detachable fittings
before reinstalling.
Frequency requirements listed in the Lubrication and Service Schedule are based on normal
operating conditions. Check filters more frequently if operating in very dusty conditions.
Table 5-1: Approved Lubricants
Extreme Pressure Gear
Lubricant
Extreme Pressure
Multipurpose Grease
SAE 85W-140,
API GL-5,
Synthetic Component
Lubricant (Synthetic
Hydrocarbon w/Phosphorus)
ISO Viscosity Grade - 220
NLGI EP2
Viscosity Index - 152
MIL-PRF-2105E
LUBRICATION AND SERVICE SCHEDULE
Periodic lubrication and service is divided into separate categories by frequency intervals. The
following paragraph discuss these requirements. Table 5-2 through Table 5-7 provide lists of
these tasks by interval. A list of periodic maintenance tables is provided below.
5-14
•
Table 5-2. Daily Maintenance Requirements
•
Table 5-3. Weekly Maintenance Requirements
•
Table 5-4. Quarterly Maintenance Requirements.
•
Table 5-5. Semi-Annual Maintenance Requirements.
•
Table 5-6. Annual Maintenance Requirements.
•
Table 5-7. Miscellaneous Maintenance Tasks
Section 5
Daily Maintenance Requirements
Table 5-2 below list maintenance tasks that shall be performed on a daily basis. These tasks
shall be performed at the end of each work day. This will ensure fluid levels are checked when
the equipment is warm and provide for correct levels at the beginning of each work day.
Table 5-2: Daily Lubrication and Service
Lube or Service Point
Service
Page No.
Front Conveyor Bearings
Grease
page 5-20
Rear Conveyor Bearings
Grease
page 5-20
Auger Bearings
Grease
page 5-21
Screed Vibrator Shaft Bearings
Grease
page 5-21
Hydraulic Fluid
Check Level
page 5-21
Engine Oil
Check Level
page 5-23
Engine Radiator
Check Level
page 5-24
Cooling Fan
Inspect
page 5-26
Truck Hitch Option Rollers
Grease
page 5-27
Engine Air Intake Piping
Inspect
page 5-27
Drive Belts
Inspect
page 5-28
Drain
page 5-28
Inspect
page 5-28
Inspect Adjust
page 5-29
Fuel Water Separator
Crankcase Breather Tube
Conveyor Chains
5-15
Section 5
Weekly Maintenance Requirements
Table 5-3 below lists maintenance tasks that shall be performed on a weekly basis or after
every 40 hours of operation, whichever comes first. These tasks shall be performed at the end
of a work day. This will ensure that the equipment is warm, thus ensuring adequate flow and
distribution of lubricants being applied.
Table 5-3: Weekly Lubrication and Service
Service
Page No.
Clean/Grease
page 5-31
Screed Depth Cranks
Grease
page 5-32
Screed Pivot Points
Grease
page 5-33
Front Wheel King Pins
Grease
page 5-34
Front Wheel Bogie Pivot Bearings
Grease
page 5-35
Truck Hitch Option Sides
Monthly Maintenance Requirements
Monthly maintenance is limited to an operational check of the parking brake system (page 535). Later in this section a procedure is provided for the performance of this operational check.
Quarterly Maintenance Requirements
Table 5-4 below list maintenance tasks that shall be performed on a quarterly basis or after
every 250 hours of operation, whichever comes first. These tasks shall be performed at the
end of a work day. This will ensure that the equipment is warm, thus ensuring adequate flow
and distribution of lubricants being applied.
Table 5-4: Quarterly Lubrication and Service
Service
Page No.
Engine Oil and Filter
Change
page 5-38
Air Cleaner
Change
page 5-41
Short Coupled Drive Shaft
Grease
page 5-46
Radiator Hoses
Check
page 5-46
Fuel Pump
Check
page 5-46
Check/Adjust
page 5-47
Auger Sections
Inspect
page 5-48
Hopper Hinge Assembly
Inspect
page 5-48
Auger/Conveyor Drive Chains
5-16
Section 5
Semi-Annual Maintenance Requirements
Table 5-5 below list maintenance tasks that shall be performed on a semi-annual basis or after
every 500 hours of operation, whichever comes first.
Table 5-5: Semi-Annual Lubrication and Service
Hydraulic Fluid and Filters
Engine Coolant
Service
Page No.
Change
page 5-49
Check
page 5-57
Annual Maintenance Requirements
Table 5-6 below lists maintenance tasks that shall be performed on an annual basis or after
every 1000 hours of operation, whichever comes first. These tasks shall be performed at the
end of a work day. This will ensure that the equipment is warm, thus ensuring adequate flow
and distribution of lubricants being applied.
Table 5-6: Annual Lubrication and Service
Service
Page No.
Repack
page 5-59
Pump Drive Box
Change Fluid
page 5-59
Auger/Conveyor Planetaries
Change Fluid
page 5-61
Drive Wheel Planetaries
Change Fluid
page 5-62
Engine Fuel Filter
Change
page 5-63
Washdown Fuel Filter
Change
page 5-66
Front Bogie Wheels
5-17
Section 5
Miscellaneous Maintenance Tasks
Table 5-7 below lists maintenance tasks that do not fall into a specific category and should be
performed on an “as needed” basis.
Table 5-7: Miscellaneous Maintenance Tasks
Service
Page No.
Hopper Wiper Arms
Adjustment
page 5-68
Swing Console
Adjustment
page 5-68
Steering Consoles and Seats
Adjustment
page 5-69
Hopper Side Extensions
Adjustment
page 5-70
Servicing and
Hydroinflation
page 5-70
Drive Tires
Preventative Maintenance Checklist
The following list is provided as a guide for periodic inspection and maintenance of the PF-161
Paver/Finisher. Establishing and performing a program of preventative maintenance will
prevent normal wear from becoming a major expense.
1. Lubricate this paver/finisher completely in accordance with the Lubrication and
Service Schedule (Table 5-2 through Table 5-7). Always perform lubrication
when the paver/finisher is still warm.
2. Check engine oil for correct operating level and change as recommended.
Keep cooling fins in engine cylinders and heads clean. Blow out dust with
compressed air occasionally. Keep battery filled to proper level. Refer to
Engine Maintenance and Operator’s Manual for complete servicing
information.
3. Tighten all hydraulic hoses and fittings before putting the paver/finisher in
service. After the first day of operation, check for leaks and retighten hoses as
necessary. Always be on the lookout for hydraulic leaks. When hydraulic leaks
are discovered, correct them immediately to prevent damage to hydraulic
components. Check hoses for cracks and/or abrasions. Replace hoses that are
worn or damaged.
4. Check the hydraulic reservoir regularly for proper level and clean fluid. Change
fluid and filters and clean strainers as directed in the Lubrication and Service
Schedule (Table 5-2).
5. Check for proper brake operation as prescribed in the procedure titled
PARKING BRAKE, later in this section (page 5-35).
5-18
Section 5
6. Check and adjust the conveyors per the instructions titled ADJUSTMENT OF
CONVEYOR CHAINS, later in this section. Conveyor chains are the most
expensive wear item on the paver/finisher. Consequently, proper adjustment is
extremely important in terms of obtaining maximum service life from these
components.
7. Check and adjust Auger/Conveyor drive chain tension per the instructions titled
ADJUSTMENT OF AUGER/CONVEYOR DRIVE CHAINS, later in this section.
8. Inspect the cast auger sections for wear. Replace if badly worn or broken.
9. Check the screed regularly for worn parts per the instructions titled CHECKING
SCREED WEAR later in this section. Refer to the paving manual for screed
adjustment and operating procedures that will help you get the maximum life
out of your screed.
10. Inspect hopper hinge assemblies. These assemblies may develop extensive
wear after considerable use. Repair or place these components as necessary.
11. Wash the paver/finisher down completely after each use in accordance with the
procedures titled CLEAN UP AND WASHDOWN earlier in this section.
12. Check the condition of wiring harnesses and battery cables regularly. Replace
wiring if insulation is worn or damaged and ensure that all connections are
clean and tight.
The following instructions support the tasks you have been instructed to perform on the
previous pages, either in the Lubrication and Service Schedule or the Preventative
Maintenance Checklist. Only qualified personnel who have been properly trained on this
equipment shall perform these procedures. The following maintenance instructions are
divided into the same categories as they are in Table 5-2 through Table 5-6 (Daily, Weekly,
Monthly, Quarterly, Semi-Annually and Annually). Read this section in it’s entirety before
attempting to perform any of the work prescribed in this section.
Daily Maintenance Tasks
The following tasks shall be performed on a daily basis, before attempting to operate the
paver/finisher.
5-19
Section 5
Front Conveyor Bearing - Grease
Lubricate the front conveyor bearings (1, Figure 5-6) using approved lubricant from Table 5-1
at the end of each day’s operation while the paver/finisher is still warm.
Figure 5-6
Rear Conveyor Bearings - Grease
Lubricate the rear conveyor bearings (1, Figure 5-7) using approved lubricant from Table 5-1
at the end of each day’s operation while the paver/finisher is still warm.
Figure 5-7
5-20
Section 5
Auger Bearings - Grease
Lubricate the auger bearings (1, Figure 5-8) using approved lubricant from Table 5-1 at the
end of each day’s operation while the paver/finisher is still warm.
Figure 5-8
Screed Vibrator Shaft Bearings - Grease
Lubricate the screed vibrator shaft bearings (1, Figure 5-9) using approved lubricant from
Table 5-1 at the end of each day’s operation while the Paver/Finisher is still warm.
Figure 5-9
Hydraulic Fluid - Check Level
The hydraulic fluid level shall be checked daily. Fluid level in the hydraulic system may be
checked whether the system is running or not. Perform the following steps to check the level
of hydraulic fluid in the system.
5-21
Section 5
!
CAUTION
System Contamination
Use care to prevent debris from entering the hydraulic tank when the cap
is removed. Even small amounts of contaminants will cause the system
to prematurely fail.
Failure to observe this admonishment may result in hydraulic system
failure.
1. Place the vehicle on level terrain.
2. Remove the fill cap (1, Figure 5-10) on the hydraulic tank.
Figure 5-10
3. Wipe off the dipstick (2, Figure 5-10) with a clean rag or paper towel.
4. Insert the dipstick.
5. Pull the dipstick out and observe the reading. The hydraulic fluid must be
present to the correct level mark on the dipstick (2, Figure 5-10).
!
CAUTION
System Damage
Only use approved hydraulic fluid in this system. Refer to Table 5-1 in this
section for a list of approved fluids.
Failure to observe this admonishment could result in system failure and/
or void warranties.
5-22
Section 5
6. If necessary, add hydraulic fluid to the system directly through the opening at
the fill cap.
7. Screw the fill cap/dipstick assembly back on the fill tank opening.
Engine Oil - Check Level
The lubricating engine oil level shall be checked daily. If more detailed information is required,
refer to the Engine Operation and Maintenance Manual. To check the level of lubricating
engine oil take the following steps:
1. Position the vehicle on level terrain.
2. Shut the engine off and wait at least 15 minutes.
3. Pull out the oil indicator dipstick (1, Figure 5-11) and wipe it off with a clean rag
or paper towel.
Figure 5-11
4. Reinsert the dipstick and pull back out for an accurate reading.
5. Oil level should be indicated up to the full level mark on the dipstick.
!
CAUTION
Engine Damage
Use only approved lubricants in this engine. Refer to Table 5-1 for a list
of approved lubricants.
Failure to observe this admonishment could result in engine failure and/
or void warranties.
6. Add oil, as necessary, through the fill cap (2, Figure 5-11) on the engine until
the oil level returns to the full mark on the dipstick.
5-23
Section 5
Engine Radiator - Check Level
The coolant level shall be checked daily. If more detailed information is required, refer to the
Engine Operation and Maintenance Manual. To check engine coolant level, perform the
following steps:
!
WARNING
Personal Injury
Never remove a pressure cap from a hot engine. Wait until the engine has
cooled to 50° C (120° F) or less before removing the pressure cap.
Always remove the pressure cap slowly, allowing any steam to escape
before fully removing the cap.
Always wear safety glasses and gloves.
Failure to observe this admonishment could result in serious burns to the
face including your eyes resulting in possible blindness.
!
CAUTION
Equipment Damage
Never use a sealing additive to stop leaks in the cooling system. This can
result in plugging of the cooling system, which over time, will restrict
system flow and compromise the system’s ability to cool the engine.
Failure to observe this admonishment could result in overheating of the
engine, eventual premature engine failure and could void you warranties.
5-24
Section 5
1. Slowly remove the pressure cap (2, Figure 5-12) from the radiator (1, Figure 512) after the water in the radiator has cooled.
Figure 5-12
2. Visually inspect the level of coolant in the radiator. The coolant should come up
to the bottom of the fill neck.
3. If the level of the coolant is low, perform the following steps to add coolant to
the system:
!
CAUTION
Engine Damage
Never add cold coolant to a hot engine. Allow the engine to cool below
50° C (120° F) before adding coolant.
Failure to observe this admonishment may result in damage to the engine
castings.
•
Create a sufficient volume of a 50%-water and a 50%-approved glycol coolant
mixture.
•
Add this mixture to the radiator until it reaches the fill neck of the radiator.
4. Reinstall the pressure cap on the radiator.
5-25
Section 5
Cooling Fan - Inspect
The cooling fan shall be inspected daily. If more detailed information is required, refer to the
Engine Operation and Maintenance Manual. To check the cooling fan, perform the following
steps:
1. Gain access to the engine and cooling fan by opening both sides of the engine
cover.
2. Visually inspect the fan (1, Figure 5-13) for cracks, loose rivets and bent or
loose blades.
Figure 5-13
3. Check to make sure the fan is securely mounted and tighten the capscrews, if
necessary.
4. If you note any problems, report your findings to the appropriate maintenance
personnel to arrange for equipment repair.
5-26
Section 5
Truck Hitch Option Rollers - Grease
Lubricate the rollers on the truck hitch option (1, Figure 5-14) using approved lubricant from
Table 5-1 at the end of each day’s operation while the paver/finisher is still warm.
Figure 5-14
Engine Air Intake Piping - Inspect
The Engine Air Intake Piping shall be inspected daily. If more detailed information is required,
refer to the Engine Operation and Maintenance Manual.To check the Engine Air Intake Piping,
perform the following steps:
1. Gain access to the engine by opening both sides of the engine cover.
2. Visually inspect the Engine Air Intake Piping (1, Figure 5-15) for wear points
and damage to piping, loose clamps or punctures that can damage the engine.
Figure 5-15
3. Report discrepancies immediately to maintenance personnel so that the proper
repairs can be performed in a timely manner.
5-27
Section 5
Drive Belts - Inspect
The Drive Belts shall be inspected daily. If more detailed information is required, refer to the
Engine Operation and Maintenance Manual. To check the Drive Belts, perform the following
steps:
1. Gain access to the engine by opening both sides of the engine cover.
2. Check the drive belts for the following:
•
Intersecting cracks
•
Longitudinal (along the belt width) cracks
•
Missing pieces of a belt
•
Frayed belt material
3. If any of the above conditions exist, contact service personnel immediately so
that timely repairs can be made.
Fuel Water Separator - Drain
Drain the fuel water separator (1, Figure 5-16) into a container on a daily basis. Dispose of
drainage in accordance with local environmental regulations.
Figure 5-16
Crankcase Breather Tube - Inspect
Visually inspect the crankcase breather tube for excessive sludge, debris or ice. During
periods of cold weather operation inspect the Crankcase Breather Tube more frequently
throughout the day.
5-28
Section 5
Conveyor Chains - Inspect/Adjust
Maintaining the paver/finisher’s two conveyors in proper adjustment will insure maximum
service life from the conveyor chains, sprockets and shafts. A properly adjusted conveyor
chain clears the ground a minimum of 127 mm (5 in.) between the drive wheels as illustrated
in Figure 5-17.
Figure 5-17
Adjustment of the conveyor chains is accomplished by moving the conveyor idler shaft and
bearing arrangements, which are located under the hopper apron.
!
WARNING
Personal Injury Hazard
Do not adjust conveyors while the engine is running. The chains could
move catching and cutting parts of your body.
Failure to observe this admonishment could result in serious injury.
5-29
Section 5
Perform the steps outlined below to adjust the conveyors:
1. Raise the hopper apron (1, Figure 5-18).
Figure 5-18
NOTE: Use care to adjust both sides of the conveyor equally. This will
prevent binding as the conveyor operates.
NOTE: On new paver/finishers, it may be necessary to perform this
adjustment several times during the break-in period to compensate for
chain run-in. This requirement will diminish as the chain is run-in and
only periodic observation will be required.
NOTE: Note that as the chain is worn, maintaining the proper adjustment
may use up all the adjustment travel. If this becomes the case, remove
some chain links. This will allow you to effectively regain the required
travel.
5-30
Section 5
2. Move the inner and outer-conveyor idler bearings (1, Figure 5-19) forward or
rearward as required by turning the conveyor adjuster screws (2, Figure 5-18
and Figure 5-19) to obtain the necessary 127 mm (5 in.) minimum ground
clearance.
Figure 5-19
Weekly Maintenance Tasks
The following maintenance tasks shall be performed at the end of the first day of each
operational week (40 hour period, not calendar week).
Truck Hitch Option Slides - Clean/Grease
Clean and lubricate the slides on the truck hitch option (1, Figure 5-20) using approved
lubricant from Table 5-1 at the end of the first day of each work week (40 hour operational
period). Perform this task while the paver/finisher is still warm.
Figure 5-20
5-31
Section 5
Screed Depth Cranks - Grease
Lubricate the screed depth cranks (1, Figure 5-21) using approved lubricant from Table 5-1 at
the end of the first day of each work week (40 hour operational period). Perform this task while
the paver/finisher is still warm.
Figure 5-21
5-32
Section 5
Screed Pivot Points - Grease
Lubricate the screed pivot points (1, Figure 5-22) using approved lubricant from Table 5-1 at
the end of the first day of each work week (40 hour operational period). Perform this task while
the paver/finisher is still warm.
Figure 5-22
5-33
Section 5
Front Wheel King Pins - Grease
Apply approved lubricant (Table 5-1) to the front wheel king pin lubrication points (1 and 2,
Figure 5-23) at the end of the first day of each work week (40 hour operational period). Perform
this task while the paver/finisher is still warm.
Figure 5-23
5-34
Section 5
Front Wheel Bogie Pivot Bearings - Grease
Apply approved lubricant (Table 5-1) to the front wheel bogie pivot bearings lubrication point
(1, Figure 5-24) at the end of the first day of each work week (40 hour operational period).
Perform this task while the paver/finisher is still warm.
Figure 5-24
Monthly Maintenance Tasks
Monthly maintenance is limited to an operational check of the parking brake.
Parking Brake - Operational Check
The following procedure checks the parking brake for proper operation. This check shall be
performed once per month, regardless of operational hours. Perform the steps outlined below
to check the operation of the parking brake.
1. Position the paver/finisher on level ground.
5-35
Section 5
2. With the engine running, position the Direction/Speed Lever (2, Figure 5-25) to
the NEUTRAL position.
Figure 5-25
3. Position the PARKING BRAKE Switch (29, Figure 5-26) to the ON position.
This will cause the brake to be applied.
Figure 5-26
5-36
Section 5
!
WARNING
Personal/Property Hazard
If the brake can be overpowered, the paver/finisher shall be taken out of
service immediately and the brake units within the final drive planetary
shall be rebuilt. Under no circumstances shall this paver/finisher be used
before this brake malfunction is fully repaired.
Failure to adhere to this admonishment may result in property damage,
personal injury and even death.
4. With the THROTTLE Switch (32, Figure 5-27) in the IDLE position, move the
Direction/Speed Control Lever (2, Figure 5-25) forward or reverse. The paver/
finisher should remain stationary, not being able to over power the brake.
Figure 5-27
5-37
Section 5
QUARTERLY MAINTENANCE TASKS
The following maintenance tasks shall be performed every quarter (3 months or 250
operational hours whichever occurs first).
•
Engine Oil and Filter - Change
•
Air Cleaner - Check/Change
•
Short Coupled Drive Shaft - Grease
•
Fuel Pump - Check
•
Radiator Hoses - Check
•
Auger/Conveyor Drive Chains - Check/Adjust
•
Auger Sections - Inspect
•
Hopper Hinge Assembly - Inspect/Repair
Engine Oil and Filter - Change
!
WARNING
Toxic Hazard
Some state and federal agencies have determined that used engine oil
may be carcinogenic and cause reproductive toxicity.
Avoid inhalation of vapors, ingestion or prolonged contact with engine
oil. If not reused, dispose of in accordance with local environmental
regulations.
!
WARNING
Personal Injury
Use care not to allow hot engine oil to come in contact with your skin.
Failure to observe this warning could result in burns and subsequent
infection could be possible.
The engine oil and oil filter shall be changed every 250 operating hours or every 3 months,
which ever occurs first. Perform this task in accordance with the procedure below. If more
detailed information is required, refer to the Engine Operation and Maintenance Manual.
1. Position the vehicle on level terrain.
5-38
Section 5
2. Engage the parking brake.
3. If necessary, start the engine and allow it to run until the water temperature
reaches 60° C (140° F).
4. Shut the engine down once the desired engine temperature is reached in the
step above.
5. Locate a container with a capacity of at least 26 L (27 qts.).
6. Locate the drain plug (2, Figure 5-28) adjacent to the WASHDOWN hose as
indicated by the placarded label (1, Figure 5-28).
7. Remove the drain plug (2, Figure 5-28) and allow the engine oil to start to drain.
Figure 5-28
8. Remove the oil fill cap (1, Figure 5-29) from the engine.
Figure 5-29
9. Clean the area around the oil filter head.
10. Remove the oil filter (1, Figure 5-30).
5-39
Section 5
!
CAUTION
Oil Leakage
Make sure the o-ring did not remain on the filter head.
Failure to remove this o-ring will result in an oil leak and possibly even
engine damage if unattended for a period of time.
11. Clean the gasket surface of the filter head.
12. Obtain a new oil filter of the correct type.
13. Fill the new oil filter with lubricating oil.
14. Apply a light film of lubricating oil to the gasket seating surface.
!
CAUTION
Equipment Damage
Use care not to over tighten the oil filter.
Failure to observe this admonishment could result in a distortion of the
threads or damage to the filter element seal.
15. Install the filter (1, Figure 5-30) as specified by the filter manufacturer.
Figure 5-30
16. Clean the sealing surface of the oil drain plug.
5-40
Section 5
17. Inspect the oil drain plug threads and replace if there are visible signs of
damage or excessive wear.
18. Install the drain plug.
19. Refer to Table 5-1 and choose an approved lubricating oil. Refer to the engine
owners manual as required for climate considerations.
20. Fill the engine with clean lubricating oil to the proper level (approximately 9.5 L
(10 qt.)) by adding oil through the engine fill opening.
21. Reinstall the engine oil fill cap (1, Figure 5-29).
22. Operate the engine and check for leaks at all filters and the oil drain plug.
Air Cleaner - Check/Change
!
CAUTION
Engine Damage
Raw Unfiltered air can cause engine damage. Never service the air
cleaner while the engine is running.
Failure to comply with this Caution could result in engine damage in a
very short period of time.
This check shall be performed every 250 operating hours or every 3 months, whichever comes
first. Perform the steps outlined below to inspect the air cleaner. If more detailed information
is required, refer to the Engine Operation and Maintenance Manual.
!
WARNING
Use care when working around the engine, surfaces may be hot.
Failure to comply with this admonishment could result in serious injury.
1. Shut the engine down.
5-41
Section 5
2. Loosen fastener (1, Figure 5-31) and remove the cover (2, Figure 5-31) from
the engine air cleaner canister so the filter element can be removed and
cleaned.
Figure 5-31
3. Set the engine air cleaner canister cover (1, Figure 5-32) aside, exposing the
air cleaner element (2, Figure 5-32).
Figure 5-32
5-42
Section 5
4. Remove wing nut (1, Figure 5-33) that secures filter element inside of filter
element canister.
Figure 5-33
5. Gently remove the filter element (1, Figure 5-34) and set aside.
Figure 5-34
5-43
Section 5
6. Clean the inside of the filter element canister (1, Figure 5-35).
Figure 5-35
7. Clean the air cleaner either using the dry or wet method as follows:
!
WARNING
Personal injury.
When using compressed air, ensure that appropriate protective clothing
is worn to protect eyes and exposed parts of the body.
Failure to adhere to this Warning could result in personal injury and even
blindness.
!
CAUTION
Equipment Damage
Air pressure should not exceed 6.89 bar (100 psi) from 3 cm (1/8 in.)
diameter nozzle located 5 cm (2 in.) away from the filter element.
Excessive air pressure can damage the air filter element and result in
more serious engine damage after periods of operation with a damaged
air filter element.
5-44
Section 5
a. To clean the air filter element using the dry method, perform the following:
•
Carefully direct the compressed air, not to exceed 6.89 bar (100 psi) at an angle onto
the inside surface of the air cleaner element.
•
Move the air jet up and down until no additional dust is being removed.
•
Visually inspect the filter element for damage and replace if necessary.
a. To clean the air filter element using the wet method, perform the following:
!
WARNING
FIre Hazard
Never use gasoline or solvents to clean the air filter element. These
substances are flammable.
Failure to adhere to this warning may result in fire or explosion and
subsequent bodily injury or even death.
•
Remove loose dirt from the filter element using a water hose.
•
Soak the filter element in a non-sudsing detergent solution for at least 15 minutes
and not more than 24 hours.
•
Swish the filter element around in the solution to loosen dirt particles and put them
into suspension in the solution.
•
Rinse the filter element from the “clean” side to the “dirty” side with a gentle stream
of water. Rinse both sides if necessary.
•
Dry the filter element by circulating warm air (less than 71° C (160° F)). DO NOT use
a light bulb to dry the filter element.
•
Visually inspect the filter element for damage and replace if necessary.
8. Replace the filter element (1, Figure 5-34) back into the canister (1, Figure 5-35)
after it and the inside of the canister have been cleaned.
9. Secure the filter element in place inside the canister using the wing nut
(1, Figure 5-33).
10. Replace the cover (1, Figure 5-32) on the canister, taking note of the top of the
cover as indicated on the inside of the cover itself.
11. Secure the cover on the canister by tightening the fastener (1, Figure 5-31) on
the cover.
5-45
Section 5
Short-Coupled Drive Shaft - Grease
Apply approved lubricant (Table 5-1) to the short coupled drive shaft lubrication points
(1, Figure 5-36) at the end of the first day of each quarter (250 hour operational period).
Perform this task while the paver/finisher is still warm.
Figure 5-36
Fuel Pump - Check
Visually inspect the Fuel Pump mounting nuts, including the tail support bracket for loose or
damaged hardware. This check must be performed every 250 operating hours or every 3
months, whichever comes first. If more detailed information is required, refer to the Engine
Operation and Maintenance Manual.
If damaged or loose hardware is noted during this inspection, contact equipment service
personnel so that the necessary repairs can be made in a timely manner.
Radiator Hoses - Check
Visually inspect the Radiator Hoses for cracks, cuts or signs of collapsing hoses. Make sure
all hoses are securely clamped. This check must be performed every 250 operating hours or
every 3 months, whichever comes first. If more detailed information is required, refer to the
Engine Operation and Maintenance Manual.
If damage is noted during this inspection, contact equipment service personnel so that the
necessary repairs can be made in a timely manner.
5-46
Section 5
Auger/Conveyor Drive Chains - Check/Adjust
!
WARNING
Never touch augers or attempt to adjust drive chains while the engine is
running. The augers could move catching and cutting parts of your body.
Failure to observe this admonishment could result in serious injury.
There should be approximately 6 mm (3/4 in.) free play in each Auger (left-hand (L.H.) and
right-hand (R.H.)). This free play can be checked by manually rotating each auger. Proper
adjustment of the auger/conveyor drive chains shall be maintained to insure smooth operation
of the paver/finisher’s feed systems and to prevent damage to the drive components due to
shock loads.
The two auger/conveyor drive chains are totally enclosed in the center case (4, Figure 5-37).
Adjustment of these chains is accomplished by moving the auger/conveyor drive
transmissions (5, Figure 5-37) up or down.
Figure 5-37
Perform the steps outlined below to adjust the auger/conveyor drive chains:
1. Loosen the mounting bolts (four on each drive transmission) (1, Figure 5-37).
2. Loosen each locknut (one on each drive transmission) (3, Figure 5-37).
3. Turn the adjusting bolts (one on each drive transmission) (2, Figure 5-37) in
order to raise or lower the drive transmissions.
4. Check the free play in each auger and make additional adjustments of the
adjusting bolts (2, Figure 5-37) until the required free play in each auger is
achieved.
5-47
Section 5
5. Tighten each lock nut (3, Figure 5-37) after the required free play is achieved
for each side of the auger.
6. Tighten each of the mounting bolts (four for each of the two drive
transmissions) (1, Figure 5-37).
Hopper Hinge Assembly - Inspection/Repair
The hopper hinge tubes (1 and 2, Figure 5-38) shall be replaced when the hinge no longer
folds smoothly. If the tubes offset by more than 3 mm (1/8 in.) when raising the hopper wings,
the hinges shall be replaced.
Figure 5-38
Auger Section - Inspection and Replacement
Auger Sections shall be inspected periodically for excessive wear and signs of damage. The
following procedure will provide some guidelines regarding this inspection.
Cast auger segments are made of high-alloy steel to produce maximum wear life. They tend
to wear the most along the outer edges and can continue to be used until they become smaller
in diameter or break off. This resulting reduction in diameter limits the auger’s ability to deliver
maximum material flow. Perform the steps outlined below to inspect the auger sections.
!
WARNING
Never stand near an auger section when the engine is running. Make sure
all personnel in the immediate area are aware of your presence near the
auger.
Never stand on an auger section.
Failure to comply with this admonishment could result in serious injury
or death.
5-48
Section 5
1. Position the paver/finisher on flat terrain.
2. Set the parking brake.
3. Shut the engine off.
4. Measure the outer diameter of each auger section. If a section has suffered
more than a 25 mm (1 in.) loss of diameter, that section shall be replaced.
5. Visually inspect each of the auger sections for visible cracks or breakage.
Replace any auger section that is broken or showing signs of cracking.
SEMI-ANNUAL MAINTENANCE TASKS
The following maintenance tasks shall be performed on a semi-annual basis (every six months
or every 500 operational hours).
•
Hydraulic Filters and Fluid - Change
•
Engine Coolant - Check
Hydraulic Fluid and Filters - Change
The hydraulic system shall be drained and all filters changed on a semi-annual basis (every
500 operational hours or every six months). This activity is broken down into the following
tasks.
•
Draining the hydraulic system
•
Changing hydraulic oil filters
•
Changing Hydraulic Tank Relief*
•
Changing Hydraulic System Charging Filter**
•
Refilling hydraulic system with fluid.
* The Hydraulic Tank relief shall be cleaned, inspected and if necessary changed every other
time this task is performed. This is a task that shall be performed on an annual basis when
the hydraulic tank is drained.
** The Hydraulic System Charging Filter should be replaced every other time this task is
performed. Replacement of this filter is required on an annual basis.
5-49
Section 5
Draining the Hydraulic System
!
CAUTION
Disabled equipment
Once the hydraulic system has been drained the vehicle is completely
disabled until the system has been refilled and is back on line.
Failure to give this detail your attention could result in unanticipated
equipment downtime and potential loss of revenue.
NOTICE
The hydraulic tank assembly is comprised of a pressurized (non-vented)
tank and an unpressurized (vented) tank. The non-pressurized tank
contains a check valve which prevents the pressurized oil from feeding
back into it, but allows free-flow between the non-pressurized tank and
the pressurized tank. When draining the hydraulic tank, it is
recommended that you drain from the pressurized tank. The pressurized
tank drain plug is located in the rear, bottom of the hydraulic tank and is
accessible through a hole in the hopper floor.
NOTE: For the sake of simplicity, locate a container of sufficient size to
collect the volume of fluid that will be collected during the draining of the
hydraulic system. The hydraulic tank holds 189 L (50 gal.) of fluid. Pumps
also hold fluid. Drained fluid must be disposed of in a manner that is in
compliance with local environmental regulations.
Hydraulic fluid may be drained using either of two methods. The first method presented is
through the manifold and fill cap of the tank, while the second method is through the tank lid
and the fill cap.
5-50
Section 5
Method One: Draining the hydraulic fluid through the manifold and fill cap.
1. Disconnect suction hose from general purpose pump or remove plug from
suction manifold. Access to the plug is through an opening in the hopper floor
(1, Figure 5-39).
Figure 5-39
2. Remove hydraulic fill cap and dip stick assembly (1, Figure 5-40).
Figure 5-40
5-51
Section 5
3. Drain non-vented (pressurized) tank through manifold (1, Figure 5-41) and
hose to collection container.
Figure 5-41
4. Wait until all fluid has been drained from pressurized side of the tank.
5. Insert hose from pump into vented (non-pressurized) tank.
6. Pump hydraulic fluid into collection container.
Method two: Draining the hydraulic fluid through the fill cap and the tank lid of the non-vented
(pressurized) tank.
1. Remove hydraulic tank fill cap and dipstick assembly (1, Figure 5-40).
2. Loosen tank lid (1, Figure 5-42) slightly (enough to all non-vented side of tank
to begin to vent), but do not remove at this time.
Figure 5-42
3. Insert hose from pump into opening on vented side of tank.
4. Pump all hydraulic fluid out of vented side of tank into collection container.
5-52
Section 5
5. Remove tank lid (1, Figure 5-42).
6. Remove hose from vented side of tank and reinsert it in the non-vented
(pressurized) side of the tank.
7. Pump all hydraulic fluid out of the non-vented (pressurized) side of the tank into
collection container.
Changing Hydraulic Oil Filters
The following describes how to change the hydraulic oil filters. Before attempting to perform
this procedure you must have completely drained all hydraulic fluid from the system as
described in the previous procedure.
1. Clean the area around the hydraulic filters.
2. Remove each hydraulic filter (1 and 2, Figure 5-43) from the filter head
assembly.
Figure 5-43
!
CAUTION
Equipment Damage
Be certain to remove any pieces of broken o-ring gasket left behind on the
gasket surface of the filter head.
Failure to adhere to this admonishment could result in hydraulic leaks,
contamination and subsequent system degradation or damage to the
system.
5-53
Section 5
4. Install one filter at a time as follows:
a. Apply a light film of hydraulic fluid to the gasket seating surface of the new
filter.
b. Fill filter completely with hydraulic fluid.
!
CAUTION
Equipment Damage
Do not over tighten the hydraulic oil filter.
Failure to adhere to this admonishment could result in distorting threads
or damage the filter element seal. Resulting in a system leak.
c. Install the new filter as specified by the filter manufacturer.
d. Repeat this process for each filter.
Removal and Cleaning of Relief (In Hydraulic Tank)
The following describes how to remove and clean the relief valve located inside the hydraulic
tank. There are no strainers in the hydraulic tank to clean. Internal tank maintenance is limited
to the removal and cleaning of this relief.
1. Insure the cap (1, Figure 5-44) has been removed from hydraulic tank and the
tank has been drained.
Figure 5-44
5-54
Section 5
2. Remove the cap screws (1, Figure 5-45) from around the hydraulic tank lid (2,
Figure 5-45).
Figure 5-45
3. Remove the tank lid (2, Figure 5-45).
4. Visually locate the internal check valve and its fittings.
5. Loosen the fittings on each side of the check valve.
6. Lift the 5 psi check valve adapter with intergal relief out of the hydraulic tank.
!
WARNING
Fire, Personal Injury
Mineral spirits are flammable. NEVER use mineral spirits while smoking
or in an environment where open flame or sparks are present.
Failure to adhere to this WARNING could result in a fire, and/or severe
personal injury even death.
7. Clean the relief with mineral spirits and then blow it dry.
8. Inspect relief and replace if damaged, otherwise reuse the same relief during
reassembly.
9. Reinsert the relief in the check valve adapter.
10. Reinstall the check valve adapter into the hydraulic tank and tighten the fitting
on each side of the adapter.
11. Reinstall the hydraulic tank lid and tighten the cap bolts removed earlier.
5-55
Section 5
Changing Hydraulic System Charge Filter
The following describes how to change the Hydraulic System Charge Filter. It makes sense to
perform this procedure when you are also draining the Hydraulic System during routine
scheduled maintenance. Perform this procedure after you have completely drained all
hydraulic fluid from the system as described in the previous procedure.
1. Disconnect and cap the hydraulic line leading (1, Figure 5-46) to the Hydraulic
System Charge Filter Assembly (2, Figure 5-46).
Figure 5-46
2. Remove charge filter. Take note of the direction the filter.
!
WARNING
Fire Hazard
Mineral Spirits are flammable. Do not perform this procedure while near
sparks, open flame or while smoking.
Failure to adhere to this Warning could result in a fire and subsequent
property damage, severe injury and/or even death.
3. Clean Charge Filter with mineral spirits and then blow-dry.
4. Inspect filter for signs of visible damage. If filter appears to be damaged, obtain
a new filter and discard the damaged filter.
5. Install new or cleaned filter to filter head, taking care to insert it in the same
direction it was in when removed.
6. Reconnect hydraulic line to Hydraulic System Charge Filter assembly.
5-56
Section 5
Refilling Hydraulic System with Fluid
1. Clean the area around the hydraulic tank. This will help prevent contamination
of hydraulic fluid.
2. Reinstall tank lid (2, Figure 5-45) if removed.
3. Fill hydraulic tank with 189 L (50 gal.) of approved hydraulic fluid (Table 5-1).
4. Fill all hoses and pump cases with hydraulic fluid.
5. Start the engine and allow the hydraulic pumps to run for a short period of time.
6. Check the level of fluid in the hydraulic tank and add fluid as necessary to finish
filling the system.
Engine Coolant - Check
!
CAUTION
Engine Damage
DO NOT use an excessive amount of antifreeze or use a high silicate
antifreeze in the cooling system.
Over concentration of antifreeze or use of high silicate antifreeze can
cause damage to the engine.
This task shall be performed every 500 operating hours or every 6 months, whichever comes
first. If more detailed information is required, refer to the Engine Operation and Maintenance
Manual.
If damage is noted during this inspection/maintenance task, contact equipment service
personnel so that the necessary repairs can be made in a timely manner.
!
WARNING
Personal Injury
Never remove a pressure cap from a hot engine. Wait until the engine has
cooled to 50° C (120° F) or less before removing the pressure cap.
Always remove the pressure cap slowly, allowing any steam to escape
before fully removing the cap.
Always wear safety glasses and gloves.
Failure to observe this admonishment could result in serious burns to the
face including your eyes resulting in possible blindness.
5-57
Section 5
!
CAUTION
Equipment Damage
Never use a sealing additive to stop leaks in the cooling system. This can
result in plugging of the cooling system, which over time, will restrict
system flow and compromise the system’s ability to cool the engine.
Failure to observe this admonishment could result in overheating of the
engine, eventual premature engine failure and could void you warranties.
1. Slowly remove the pressure cap from the radiator after the coolant in the
radiator has cooled.
NOTICE
Antifreeze is essential in every climate.
It broadens the operating temperature by lowering the coolant freezing
point and by raising it’s boiling point.
It contains corrosion inhibitors that also protect the cooling system from
corrosion and provide longer component life.
2. Check the antifreeze concentration in the radiator using a reliable, easy to read
refractometer. Coolant should be at a level to protect the engine year-round to
-25° C (-32° F).
3. If necessary add antifreeze, using a mixture of 50% water and 50% ethylene
glycol or propylene glycol-based antifreeze.
ANNUAL MAINTENANCE TASKS
The following maintenance tasks shall be performed on an annual basis (every year or every
1000 hours of operation whichever occurs first, always at the beginning of a paving season).
5-58
•
Front Bogie Wheels - Repack
•
Pump Drive Box - Change Fluid
•
Auger/Conveyor Planetaries - Change Fluid
•
Drive Wheel Planetaries - Change Fluid
•
Washdown Fuel Filter - Change
•
Engine Fuel Filter - Change
Section 5
Front Bogie Wheels - Repack
The Front Bogie Wheels shall be repacked every 1000 operating hours or on an annual basis,
whichever comes first. Repack the front bogie wheels (1, Figure 5-47) using approved grease
(Table 5-1).
Figure 5-47
Pump Drive Box - Change Fluid
The Pump Drive Box fluid shall be changed every 1000 operating hours or on an annual basis,
whichever comes first. Refer to Figure 5-48 and use only approved lubricants. Refer to
Table 5-1 for a list of approved lubricants. Perform the following to change the fluid in the pump
drive box.
1. After the vehicle is warmed up, park it on level terrain.
2. Obtain a container that is suitable to collect the fluid from the pump drive box
(approximately 2.8 L (6 pints)).
5-59
Section 5
3. Remove the drain plug (1, Figure 5-48) and allow the fluid to drain into the
container.
Figure 5-48
4. Wait for all the fluid to drain.
5. Reinstall the drain plug (1, Figure 5-48).
6. Remove the fill plug (3, Figure 5-48) from the pump drive box.
7. Remove the level plug (2, Figure 5-48).
8. Fill the pump drive box with approximately 2.8 L (6 pints.) of approved lubricant.
9. Visually confirm the pump drive box is filled to a sufficient level by noting
lubricant being up to the level plug opening.
10. Reinstall the level plug (2, Figure 5-48) and the fill plug (3, Figure 5-48).
5-60
Section 5
Auger/Conveyor Planetaries - Change Fluid
The Auger/Conveyor Planetary fluid shall be changed every 1000 operating hours or on an
annual basis, whichever comes first. Change the fluid in the auger planetaries (Figure 5-49)
using approved fluid (Table 5-1) only. Perform the following when changing the fluid in the
Auger/Conveyor planetaries:
Figure 5-49
1. Park the vehicle on level terrain.
2. Remove the drain plug (3, Figure 5-49) and the fill plug (1, Figure 5-49).
3. Allow fluid to drain from planetary until finished.
4. Remove level plug (2, Figure 5-49).
5. Reinstall the drain plug (3, Figure 5-49).
6. Add approved lubricant through the fill plug (1, Figure 5-49).
7. Visually confirm that the appropriate amount of lubricant has been added to the
planetary by observing that fluid level has risen to the level plug.
8. Reinstall the level plug and the fill plug (2 and 3, Figure 5-49).
5-61
Section 5
Drive Wheel Planetaries - Change Fluid
The Drive Wheel Planetary fluid shall be changed every 1000 operating hours or on an annual
basis, whichever comes first. Change the fluid in the drive wheel planetaries using approved
fluid (Table 5-1). Follow the guideline provided below when changing this fluid.
1. Allow oil in wheel ends to have reached operating temperature.
2. Position the paver/finisher on level ground with the oil drain plug (1, Figure 550) in the 6 o’clock position (4, Figure 5-50).
Figure 5-50
!
WARNING
Personal Injury.
Avoid contact with hot oil or components.
Failure to comply with this Warning could result in personal injury,
including severe burns.
NOTICE
Do not allow oil to drain onto ground.
Failure to adhere to this Notice may place you and your organization in
direct violation of federal and local environmental regulations.
3. Place a container under the oil drain plug (1, Figure 5-50) and remove plug.
4. Allow oil to drain.
5-62
Section 5
5. Replace the oil drain plug.
6. Remove the Oil Fill (2, Figure 5-50) and Level (3, Figure 5-50) plugs from the
wheel.
7. Add oil until oil is level with the bottom of the Level (3, Figure 5-50) plug hole.
Refer to Table 5-1 for a list of approved lubricants.
8. Clean and replace Level (3, Figure 5-50) and Oil Fill (2, Figure 5-50) plugs and
tighten.
9. Repeat procedure for other wheel end unit.
Engine Fuel Filter - Change
The engine fuel filter (1, Figure 5-51) shall be changed every 500 operating hours or every 6
months, whichever comes first. There are two types of fuel filters, either of which may be used
on your engine. Only perform one of these procedures depending on how your engine is
equipped. Determine which type of fuel filter you have on your engine and refer to the
appropriate procedure below. If more detailed information is required, refer to the Engine
Operation and Maintenance Manual.
Figure 5-51
Changing a Canister - Type Fuel Filter
If your paver/finisher is equipped with a canister-type fuel filter, perform the following
procedure.
1. Position the vehicle on level ground.
5-63
Section 5
!
WARNING
Personal Injury, Explosion and Fire Hazard
Flammable fluids will be present during the performance of this task. Do
not smoke or allow any bystanders to smoke while you are performing
any part of this procedure. Do not allow any activity to be performed that
could result in the generation of an open spark.
Failure to adhere to these guidelines could result in fire, explosion,
3. Locate the fuel filter.
4. Lift up on the filter drain lever and allow fuel to drain from the filter for
approximately 5 seconds.
5. Clean all debris from around the canister lid.
6. Remove the filter lid and canister. If you cannot remove the lid by hand, you can
use a crescent wrench.
7. Twist the canister and it will break away from the filter lid. The canister is
incinerable.
8. Verify that the o-ring is also removed from the canister lid. If necessary, remove
it and discard.
9. Insert a new filter element in the canister lid.
10. Lubricate the new o-ring that came with the filter element using clean engine oil.
!
CAUTION
Equipment Damage
Use care not to over tighten the fuel filter.
11. Replace the canister lid back on the canister body and hand-tighten by turning
clockwise (CW). Use of a wrench to tighten the canister lid is not
recommended.
5-64
Section 5
Changing a Spin-On-Type Fuel Filter
If your paver/finisher is equipped with a Spin-On-type fuel filter, perform the following
procedure.
1. Position the vehicle on level ground.
!
WARNING
Personal Injury, Explosion and Fire Hazard
Flammable fluids will be present during the performance of this task. Do
not smoke or allow any bystanders to smoke while you are performing
any part of this procedure. Do not allow any activity to be performed that
could result in the generation of an open spark.
Failure to adhere to these guidelines could result in fire, explosion,
3. Locate the fuel filter.
NOTICE
Be sure to drain the water/fuel into a container and dispose of in
accordance with local environmental regulations. Do not drain onto the
ground.
4. Use the filter drain valve to drain from the filter for approximately 5 seconds.
5. Clean the area around the fuel filter head.
6. Disconnect the water-in-fuel sensor connection from the wiring harness.
7. Remove the fuel filter by unbuckling the latch and unscrewing the filter.
8. Lubricate the filter o-ring with clean lubricating oil.
!
CAUTION
Equipment Damage
Use care not to over tighten the fuel filter.
5-65
Section 5
9. Install the fuel filter as specified by the filter manufacturer.
10. Reconnect the water-in-fuel sensor to the wiring harness.
Washdown Fuel Filter - Change
Replace the WASHDOWN Fuel Filter (1, Figure 5-52) as follows:
Figure 5-52
1. Clean the area around the Washdown Fuel Filter head.
2. Remove the Washdown Fuel Filter.
!
CAUTION
Fuel Leakage
Make sure the o-ring did not remain on the filter head.
Failure to remove this o-ring will result in an fuel leak and possibly cause
a significant waste of fuel during the washdown process.
4. Obtain a new filter of the correct type.
5. Fill the new oil filter with diesel fuel.
6. Apply a light film of lubricating oil to the gasket seating surface.
5-66
Section 5
!
CAUTION
Equipment Damage
Use care not to over tighten the filter.
7. Install the filter as specified by the filter manufacturer.
MISCELLANEOUS MAINTENANCE TASKS
The following maintenance tasks do not fall into any specific category and should be
performed on an “as needed” basis. Read and become familiar with these tasks so that when
it is necessary to perform one of them you know where the information is and basically what
is involved. These miscellaneous maintenance tasks are:
•
Adjustment to Hopper Wiper Bars
•
Adjustment of Swing Console
•
Adjustment of Steering Consoles and Seats
•
Adjustment of Hopper Side Extensions
•
Drive Tire Servicing and Hydroinflation
5-67
Section 5
Adjustment of Hopper Wiper Bars - As Required
Hopper wiper bars (1, Figure 5-53) are provided to prevent paving material from accumulating
in the area between the wing rear plates and the hopper bulkhead.
Figure 5-53
The wiper bars should be adjusted to lightly contact the bulkhead. A gap between the bulkhead
and the wiper bars themselves should not exist, as this would allow material to accumulate
and work through.
Adjustment of Swing Console - As Required
The swing console height can be adjusted to any of three positions, by removing the four
screws (1, Figure 5-54) and raising or lowering the console to a more comfortable operating
level. Secure the console-height setting by re-installing the four screws (1, Figure 5-54).
Figure 5-54
5-68
Section 5
Adjustment of Steering Consoles and Seats - As Required
The steering consoles can be tilt adjusted to any one of three positions. Simply loosen the
allen nut on the steering column (1, Figure 5-55) and reposition the steering wheel to a
comfortable position. Then, retighten the allen nut.
Figure 5-55
The operator’s seat can be adjusted fore and aft. Move the spring loaded lever (2, Figure 555) to the left, releasing the slide mechanism and position the seat to the desired position.
The seat can also be height adjusted to accommodate the operator. To adjust the height of
the seat, loosen the allen nut (3, Figure 5-55) and position the seat to the desired height. Then
tighten the allen nut, securing the seat to that height on the post.
5-69
Section 5
Adjustment of Hopper Side Extensions - As Required
Hopper side-extension plates (1, Figure 5-56) are provided to help reduce material spillage
from dump trucks. They can be repositioned as required to accommodate the average
overhang length of the majority of dump trucks on your job.
Figure 5-56
Drive Tire Servicing and Hydroinflation - As Required
We recommend that this task be performed at a tire service store rather than in the field by
equipment operators. Tire service stores are properly equipped and have trained personnel to
perform needed services safely.
OFF SEASON STORAGE
This procedure shall be followed at the end of a paving season or anytime the paver/finisher
will be idle for an extended period. This is to protect the paver/finisher and ensure its
availability when paving operations resume.
1. Clean the paver/finisher thoroughly, removing all paving material. Refer to the
paragraph titled, “Cleanup and Washdown” presented earlier in this Section for
detailed instructions pertaining to the proper method of cleaning the paver/
finisher.
2. Inspect the paver/finisher thoroughly for worn or damaged components and
repair or replace, as required.
3. Fill the fuel tank with fuel.
5-70
Section 5
4. Drain the engine crankcase, change engine oil filter and refill engine crankcase
with recommended lubricant. Refer to the Approved Lubricants Table 5-1 for a
list of recommended products.
5. Replace the air filter.
6. Refer to the engine manual for further recommendations regarding off-season
storage.
7. Disconnect the battery. If necessary to prevent freezing store the battery. Be
sure to charge the battery before reinstalling.
8. Lubricate the entire paver/finisher as recommended in the lubrication and
Service Schedule, Table 5-2.
9. Grease the bottom of the screed to prevent rusting and scaling.
5-71
Section 5
5-72
SECTION 6 - TROUBLESHOOTING
6-1
Section 6
TROUBLESHOOTING
TROUBLESHOOTING
GENERAL
This section contains general troubleshooting guidelines for the PF-161 Paver/Finisher.
Troubleshooting for the paver/finisher in this manual is limited to the correcting fluid levels and
cleaning or changing filters.
Additionally a brief table of possible trouble symptoms are included for the Blaw-Kontrol®
Ultrasonic Grade Control System.
Other malfunctions are considered beyond the scope of an operator level task and should be
referred to your local maintenance/service organization or your nearest Ingersoll-Rand
Distributor.
The topics in this section are listed below.
•
General Fault Isolation Tips/Information
•
Alarms Indications and Remedies
!
WARNING
When performing troubleshooting procedures it is critical to observe all
safety precaution listed both in the body or these procedures and those
listed in Section 1, SAFETY of this manual. Make yourself very familiar
with the contents of Section 1 before attempting any of these procedures.
Failure to observe this admonishment could result in serious injury, both
disabling and lethal.
General Fault Isolation Tips/Information
Improper operation and maintenance is the most frequent cause of machinery failures and
problems. In the event of a failure it is recommended that you read through this manual.
If you are unable to determine the cause of the problem, contact your local Ingersoll-Rand
Distributor.
6-2
TROUBLESHOOTING
Section 6
How This Section Works
This section is laid out in two parts.
First are general troubleshooting guidelines. These guidelines review some basic rules that, if
followed will increase your chances of successfully isolating a defective component, making a
repair and returning the machine to service as quickly as possible.
Third is a listing of alarms that may be displayed to alert the operator to a maintenance task
that requires immediate attention. These tasks are typically the correcting of a fluid level or
replacement of a dirty filter. Maintenance tasks to correct these conditions will also be
referenced in this listing.
General Troubleshooting Guidelines
The following are recommendations that if followed will result in shorter machine downtime
and/or correct information being passed on to service personnel in the event of a failure
beyond the scope of the operator.
Always be aware of the status of the preventive maintenance on your machine. Keep these
tasks current. It is unlikely a failure will occur if these tasks are performed at the recommended
interval using the recommended material (lubricants and fluids).
If a failure does occur, do not rely on your memory in terms of the exact symptoms. Always be
aware of how your machine is performing. Symptom recognition is one of the most critical
aspects of troubleshooting any machine. At a minimum take written note of the following when
a failure occurs:
•
General Failure Description - What happened?
•
Tasks Being Performed/Machine Status - What were you doing and what system(s)
were operating on the paver/finisher at the time of the failure.
•
Miscellaneous - Were there any unusual sounds, smells or other symptoms (i.e.,
smoke, spark, smell of burning material, flickering control panel lights, etc.).
When a malfunction is noticed, address it immediately. If a malfunction is ignored, it could
result in a cascading set of additional failures. A simple problem (low engine oil) if ignored
could quickly turn into a serious machine failure causing lost equipment time and expensive
repairs.
6-3
Section 6
TROUBLESHOOTING
Alarms Indications and Remedies
The following alarm indications could be caused by an improper fluid level or dirty filter. If any
of these conditions exist and the remedy listed does not correct the problem, get in touch with
your service organization or local Ingersoll-Rand Distributor immediately. Refer to the Figure
6-1 for a photograph of these alarm indicators and refer to Table 6-1 for a list containing each
indication and a recommended remedy.
Figure 6-1
Table 6-1: Malfunction Remedy Table
SYMPTOM
6-4
CAUSE
REMEDY
(5, Figure 6-1) is
illuminated
Scheduled maintenance has
not been performed
Review scheduled maintenance tasks
and perform all tasks required to bring
this machine up to date in terms of
routine scheduled maintenance.
Water In Fuel Indicator
(7, Figure 6-1) is
illuminated
Water has been detected in
the fuel system.
Refer to the Section 5 of this manual
and drain the Water/Fuel separator. This
task should be performed on a daily
basis.
Check Engine Indicator
(9, Figure 6-1) is
illuminated
Problem with an engine fluid
level or component.
Check instruments, make sure Oil
Pressure gauge reads above 30 psi,
Water Temperature gauge reads below
230° F, Oil Temperature gauge reads
below 230° F and Battery Gauge reads
above 10.5 Volts. If any gauge reads out
of specification stated above refer to the
specific symptom below. Otherwise
contact your service organization as
soon as possible.
TROUBLESHOOTING
SYMPTOM
Section 6
CAUSE
Hydraulic Filter Indicator
(13, Figure 6-1) is
illuminated
The hydraulic filter indicator
will always illuminate when
the machine is initially
started and will remain
illuminated until the
hydraulic fluid heats up to
normal operating
temperature (approximately
10 minutes). If the indicator
remains lit for more than 15
minutes the hydraulic
system is restricted and
maintenance is immediately
required.
Oil Pressure Gauge reads
less than 30 psi when the
engine is operating at
2200 RPM
For some reason the engine
is not developing adequate
oil pressure.
REMEDY
Possible Equipment Damage.
When the hydraulic filter indicator (13,
Figure 6-1) remains illuminated for
extended periods (1 hour or more),
replace the hydraulic filters. Failure to
do so, could result in hydraulic system
damage or degraded hydraulic system
performance.
Check that oil level is correct, refer to the
Section 5 of this manual. Correct if
necessary.
Check that the oil filter was changed
when last required. Correct if necessary.
Refer condition to local service
organization.
Water Temperature
Gauge reads above
230° F
For some reason the engine
is not being properly cooled.
Check performance of scheduled
maintenance on the cooling system
(Radiator).
Look for coolant leaks, if leaks are
discovered, refer problem to local
service organization immediately.
If necessary add engine coolant/water
solution to radiator, refer to Section 5 of
this manual.
Turn problem over to local service
organization if you cannot correct
problem as stated above. Do not operate
this machine until the problem is
corrected.
reads above 230° F
Battery Gauge is reading
less than 10.5 volts.
For some reason lubricating
oil is not keeping engine
friction down to acceptable
levels and internal
temperatures are rising to
dangerous levels.
For some reason the battery
charge is not being
maintained.
Check level of lubricating oil as
described in Section 5 of this manual.
Check to make sure all preventive
maintenance has been performed.
Refer problem to local service
organization. Do not operate this
machine until the problem is corrected.
Refer problem to local maintenance
organization.
6-5
Section 6
TROUBLESHOOTING
Blaw Kontrol® Ultrasonic Grade Control System Troubleshooting
Table 6-2 provides a list of various fault indications associated with the Blaw Kontrol Ultrasonic
Grade Control System and a recommended remedy or set of remedies for each fault
indication.
Table 6-2: Blaw-Kontrol® Malfunction Remedy Table
SYMPTOM
No Display
CAUSE
No power being supplied
to the handset.
REMEDY
Check:
Paving Machine auto/manual
switching.
Paving Machine power supply
Cable connections/damage to
cables
Up/down arrows light,
but there is no control
to paver/finisher
to adjusting cylinder
solenoids
Handset in manual mode.
Paver/finisher in manual mode/
standby
Check cables/connectors for
continuity
6-6
Er1
Sonic sensor out of range
Raise or lower sonic sensor
(adjusting cylinders)
Er2
Sonic sensor has no
reference
Check/replace wire bail
Er4
Sensor abnormality
Remove and reconnect paver/
finisher power plug.
000
Sensor operation outside
“Working Window”
Check “Working Window” settings
Check mechanical integrity of
sensor mountings
Check for sensor field-of-view
obstructions
SOS
Handset not
communicating with
sensor
Check cables and connections
Display shows
erroneous segment
characters or Both
upper and lower
displays show numbers
“Power-up” glitch
Reconnect main power connection
CAL flashes when
selecting “auto”
Sensor not calibrated
Re-calibrate sensor
TROUBLESHOOTING
SYMPTOM
Section 6
CAUSE
REMEDY
Blaw-Kontrol is
sluggish in operation
(paver slow to react)
Long elongated waves
in material
Incorrect settings
Check sensitivity, pulse width,
deadband and working window.
Adjusting cylinders
appear slow in reaction
Long elongated waves
in material
Mechanical/Hydraulic
settings
Check adjusting cylinder solenoids
and restrictors
Blaw-Kontrol reacts too
quickly
Incorrect settings
Check sensitivity and output pulse
width
Movement in one
direction only
(Adjusting cylinder
moves up only but not
down or vise versa)
to one adjusting cylinder
solenoids
Check wiring, cables and
connectors
Paver has “jitter” partially evident when
paver is paused
(hunting)
Sensitivity too high
Lower sensitivity
Material shows signs of
irregular ripples
Deadband too wide.
Working window too
small
Lower deadband
Increase Working Window
“Doesn’t hold levels”
Incorrect setup
Read manual
6-7
Section 6
6-8
TROUBLESHOOTING
SECTION 7 - TECHNICAL
SPECIFICATION
7-1
Section 7
GENERAL
This section contains the technical specification for the PF-161 Paver/Finisher. The following
specification data is presented in this section.
•
Machine Identification
•
Environmental Specifications
•
Physical Specifications
•
Miscellaneous Specifications
Machine Identification
Name of Machine
:
PF-161 Paver Finisher
Type of Machine
:
Paver/Finisher
Serial Number or Product Range
:
Production
Name and Address of Manufacturer
:
Ingersoll-Rand
312 Ingersoll Drive
Shippensburg, Pennsylvania 17257-1295
Environmental Specifications
This machine meets all federal EPA and OSHA requirements.
Physical Specifications
Dimension
7-2
Specification
Tractor Width (Hopper Sides Up)
2.5 m (98.5 in.)
Tractor Width (Hopper Sides Down)
3.22 m (125 in.)
Gage Width (center-to-center of drive
wheels)
1994 mm (78.5 in.)
Wheelbase
1905 mm (75 in.)
Length (Overall with Wedge-Lock® Screed)
5.24 m (17 ft., 2-3/8 in.)
Section 7
Dimension
Specification
Length (Overall with Omni Screed® 1A)
5.39 m (17 ft., 8-3/8 in.)
Weight (Tractor Only)
9,775 kg (21,550 lbs.)
Weight (Total with Wedge-Lock® Screed)
10,954 kg (24,150 lbs.)
Weight (Total with Omni Screed® IA)
11,567 kg (25,500 lbs.)
Refer to Figure 7-1 for a diagram showing the overall dimensions of the paver/finisher.
Figure 7-1
7-3
Section 7
Miscellaneous Specifications
Loading Ramp Angle
11°
Engine
Elite® Series, EPA certified, 4 cylinder,
turbocharged diesel
Manufacturer
Cummins
Type/Model
4BTA 3.9
Displacement
3.92 L (239 cubic in.)
Horse Power
107 @ 2100 rpm
Cooling System Capacity
24.6 L (26 qts.)
Fuel System Capacity
144 L (38 gal.)
Electrical System
12 Volt-negative ground, with 105 Ampere
alternator
Traction Drive
Independent, hydrostatic direct drive system.
Low Range @ 2100 rpm
0-59.7 m/min. (196 fpm)
High Range @ 2100 rpm
0-15.9 kph (9.9 mph)
Reverse
Full reverse in any of two speed ranges.
Traction Lock System
Provides full time tractive effort at both drive
wheels
Paving Width
5.79 m (19 ft.)
Hydraulic System Capacity
151 L (40 gal.)
Brakes
Primary-hydrostatic drive, Secondary-hydraulic
parking brakes (spring loaded)
Front Suspension
7-4
Wheels
Four steerable 305 mm (12 in.) wide x 559 mm
(22 in.) dia. solid rubber tired wheels
Mounting
Offset tandem bogie frame
Weight distribution
Proportional split (40 - 60%) between the front
and rear sets of bogies
Steering
Tie rod synchronized steering cylinders (one on
each side) are mounted on the outside of the
bogie frame
Section 7
Rear Suspension
Two 14:00 x 20 low pressure 182 to 260 kPa
(25 to 35 psi), sand ribbed, high flotation tires,
hydroinflated to 75%.
Pivot Steering
Available for power assisted steering in tight
quarters.
Front End
Either Oscillating Push Rollers or a Truck Hitch
Push Rollers
Two bearing equipped push rollers mounted on
a 2502 mm (98.5 in.) wide oscillating frame.
Truck Hitch
Two bearing equipped push rollers mounted on
an oscillating frame with electric/hydraulic
actuated roller equipped clamp arms.
Maximum Arm Opening
3302 mm (130 in.)
Minimum Arm Opening
1829 mm (72 in.)
Degree of Swivel
±8 °
Drift from Center (right to left)
305 mm (12 in.) Automatically Self Centering
Hopper
8T (9.8 ton) 5.1m³ (181 ft.³) capacity
Truck Entry Width
3048 mm (120 in.)
Truck Dump Clearance (minimum)
565 mm (22.25 in.)
Power Flow Gates
Two separately operated, electrically controlled,
adjustable flow gates.
Dual Feed System
Separate, infinitely variable speed, hydrostatic
planetary drive for right and left side feed
systems.
Conveyors
Two conveyors, R.H and L.H sides
Conveyor Tunnel Opening
1362 mm (53.625 in.)
Conveyor Floor Plate Thickness
10 mm (.375 in.)
Augers
Bolt on replaceable, high alloy, cast steel hemiscrew sections.
Auger Diameter
356 mm (14 in.)
Auger Flight Thickness
16 mm (5/8 in.)
Auger Height Adjustment (above
grade)
114-279 mm (4.5-10.5 in.)
Auger Speed Maximum @ 2100
Engine rpm
122 rpm
7-5
Section 7
Automatic Feed Control System
Mat Kontrol® II with a choice of either Paddle
Sensors or Ultra 3s® Sensors.
Mat Kontrol® II with Paddle Sensors
Electric/hydraulic control arrangement that
automatically controls both the “on-off” action
and the infinitely variable operating speed of
the dual feed system.
Mat Kontrol® II with Ultra 3s®
Sensors
Same result as above, but utilizes a sounding
system similar to a sonar to determine the
amount of material present at the augers, then
feedback controls manage the delivery of
material.
Ventilation Control System
Machine mounted heat and fume extraction
system.
Washdown System
Pressurized diesel fuel washdown system with
a 10.7 m (35 ft.) hose.
Screed Options/Choices
7-6
Screed Heaters
One of the following screed heater options are
on your machine
Diesel Only Heaters
Unitized, diesel fueled, SureFire® burner/
blowers with manual activated spark igniter.
Diesel Heaters with ATIC
Unitized, diesel fueled, SureFire® burner/
blowers with Automatic Temperature and
Ignition Control (ATIC).
Propane Heaters with ATIC
Same as above but using propane as a fuel.
Wedge-Lock® Screed
Basic 8 ft. (2.44 m) fixed width vibratory screed
with a one piece 623 mm (24.5 in.) wide x 13
mm (0.5 in.) thick, bolt-on replaceable screed
plate.
Standard Paving Range (with cut-off
plates)
1.8-2.4 m (6-8 ft.)
5.8 m (19 ft.)
Paving Depth Range
6-203 mm (0.25-8.0 in.), optional to 305 mm
(12 in.)
Vibrator Speed
52 Hz (0-3100 rpm)
Center Crown
Mechanical dual crown kit provides
simultaneous adjustment of center lead and tail
crown from 76 mm (3 in.) positive to 19 mm
(0.75 in.) negative.
Heat
Section 7
See screed heater data above.
Wedge-Lock Screed Extensions
Optional 152 mm (6 in.), 305 mm (12 in.), 610
mm (24 in.) and 914 mm (36 in.) extensions for
the basic screed.
2.5/5B Hydraulic Screed Extensions
Optional hydraulic telescoping extensions.
Width Increase
Maximum 762 mm (2.5 ft.) each side while
paving
Slope Control
Manual up to a maximum of 25 mm (1 in.) in
305 mm (12 in.) positive (at any extended
width) or negative (fully extended)
Power Slope Option for
2.5/5B Hydraulic Extensions
On the go slope control for each extension
relative to the main screed up to 25 mm (1 in.)
in 305 mm (12 in.) positive (at any extended
width) or negative (fully extended).
Berm Attachment Option for 2.5/5B
Hydraulic Extensions
Replaces the standard screed plate
arrangement to provide up to 102 mm (4 in.) of
vertical rise in 610 mm (24 in.) at the outer end
of each extension.
OmniScreed® IA
Basic 8 ft. (2.44 m) power extendible, vibratory
screed.
Standard Paving Range (with cut-off
plates)
1.83-4.0 m (6-13 ft. 1-1/2 in.)
Maximum Paving Width (with
optional Wedge-Lock® extensions)
5.23 m (17 ft., 2 in.)
Paving Depth Range
6-203 mm (0.25-8 in.) optional to 305 mm (12
in.)
Vibrator Speed
42 Hz (0-2500 rpm)
Center Crown
Choice of either mechanical or hydraulic
powered dual crown kits provides simultaneous
adjustment of center lead and tail crown from
76 mm (3 in.) positive to 19 mm (0.75 in.)
negative.
Extension Power Slope Range
Up to 25 mm (1 in.) in 305 mm 12-in. positive at
any extended width (0 to 8%).
Heat
See screed heater data
®
AVAILABLE OPTIONS
Front Wheel Power Assist
Provides up to 20% more tractive effort in the
machines paving speed range
7-7
Section 7
7-8
Material Indicator Kit
Provides audible warning to the operator when
material level drops below a preset threshold at
the conveyor entry tunnel.
Blaw-Kontrol® II
Automatically maintains the elevation and
transverse (side-to-side) slope of a paver/
finisher’s screed to preset specification
parameters, with respect to a single reference.
Slope resolution is .005%.
UltraEye® V Grade Sensor
Ultrasonic (non-contacting) grade sensor.
Resolution is 0.508 mm (0.020 in.).
Automatic Level Control
Also known as a joint matcher. Resolution is
3.175 mm (.1259 in)
Floating Beam Reference
Eliminates need for stringline references.
Available in 6.10, 9.14 and 12.20 m (20, 30 and
40 ft.) lengths and sets of two for dual grading
purposes.
Mat Reference
Provides a 16.77 m (55 ft.) mobile grade
referencing system.
55 Ft. (16.77 m) Mobile Referencing
System
Combines the Floating Beam reference and
Mat reference.
Additional Operators Umbrella
Second 1372 mm (54 in.) square operator’s
umbrella.
SECTION 8 - FUEL AND
LUBRICANT SPECIFICATIONS
8-1
Section 8
GENERAL
An extended warranty is available at no charge when you use genuine IR lubricants and parts.
See your authorized IR dealer for details.
Lubrication is an essential part of preventive maintenance, affecting to a great extent the
useful life of the machine. Periodic lubrication of the moving parts reduces to a minimum the
possibility of mechanical failures. For maximum machine life and performance, we
recommend the use of genuine IR brand lubricants.
Different lubricants are needed and some components require more frequent lubrication than
others. Therefore, it is important that the instructions regarding types of lubricants and the
frequency of their application be explicitly followed.
Lubrication tasks and suggested intervals are covered in Section 5 of this manual. Details
concerning fuel, oil and other lubricants are provided in this section. A regular service program
should be geared to the lubrication tasks covered in Section 5 of this manual. The suggested
intervals are based on average operating conditions. In the event of extremely severe, dusty
or wet operating conditions, more frequent lubrication than specified may be necessary.
All oil levels are to be checked with the machine parked on a level surface and while the oil is
cold, unless otherwise specified.
On plug type check points, the oil levels are to be at the bottom edge of the check port.
All grease fittings are SAE STANDARD unless otherwise indicated. Grease non-sealed fillings
until grease is seen extruding from the fitting.
Over lubrication on non-sealed fittings will not harm the fittings or components, but under
lubrication will definitely lead to a shorter lifetime.
Unless otherwise indicated, items not equipped with grease fittings (linkages, pins, levers,
etc.) should be lubricated with oil once a week. Motor oil, applied sparingly, will provide the
necessary lubrication and help prevent the formation of rust. An anti-seize compound may be
used if rust has not formed. Otherwise, the component must be cleaned first.
Grease fittings that are worn and will not hold the grease gun, or those that have a stuck check
ball, must be replaced.
To prevent minor irregularities from developing into serious conditions several other services
or checks are recommended for the same intervals as the periodic lubrication.
1. Thoroughly wash all fittings, caps, plugs, etc. with non-flammable, non-toxic
cleaning solution before servicing. This will prevent dirt from entering these
components while lubricating.
2. Lubricants must be at operating temperature when draining.
8-2
Section 8
3. During regular lubrication service, visually check the entire unit in regard to
capscrews, nuts and pins being properly secured.
4. Spot check several capscrews and nuts for proper torque. If any are found
loose, correct the issue and make a more thorough investigation.
5. If a defect is detected that requires special maintenance service, stop the
operation of the machine until the defect has been corrected. If necessary
contact a local Ingersoll-Rand distributor for assistance.
Periodic lubrication requirements are listed in the following Lubrication Chart. These
requirements include lubricant checks and greasing designated areas of the machine.
FLUID CAPACITIES
The following fluid capacities are provided for servicing personnel who must perform machine
maintenance in remote locations where complete shop facilities and resources are not
available. These capacities will give the servicing personnel an approximation of the fluid
capacities of the components being serviced. Always ensure that the specified method of
check for adequate fluid levels is used.
Table 8-1: Fluid Capacities
Fluid/Oil
Approximate Capacity
Diesel Oil
144 L (38 gal.)
Hydraulic Oil
189 L (50 gal.)
Engine Oil
9 L (10 qts.)
Engine Coolant
24.6 L (26 qts.)
HYDRAULIC OIL REQUIREMENTS AND SPECIFICATIONS
The quality of the hydraulic oil is important to the satisfactory performance of any hydraulic
system. The oil serves as the power transmission medium, system coolant and lubricant.
Selection of the proper oil is essential to ensure proper system performance and life. Hydraulic
oil used in this machine should meet the following criteria:
•
ISO VG 46 with anti-wear additives
•
VI 140 (Min)
8-3
Section 8
LUBRICATING OIL/GREASE (EXCEPT ENGINE)
I.
Extreme Pressure Gear Lubricant shall meet the following criteria:
•
SAE 85W - 140W
•
API GL-5
•
MIL PRF 2105E
II. Extreme Pressure Multipurpose Grease shall meet the criteria of NLGI EP2.
III. IR Synthetic Component Lubricant shall meet the following criteria:
•
Synthetic Hydrocarbon with Phosphorus
•
ISO VG 220
•
VI 152
ENGINE LUBRICATING OIL SPECIFICATIONS
NOTE: For latest applicable engineering lubricating oil specifications,
contact engine manufacturer, distributor or your Ingersoll-Rand
distributor.
•
8-4
IR Multi-Purpose Premium Engine Oil - SAE 15W-40
Section 8
DIESEL FUEL SPECIFICATIONS
Table 8-2: Diesel Fuel Specifications
Viscosity (ASTM D-445)
1.3 to 5.8 centistrokes per second at 40° C
(104° F)
Cetane Number (ASTM D-613)
40 minimum except in cold weather or in
service with prolonged idle, a higher cetane
number is desirable.
Sulfur Content (ASTM D-129 or 1552)
Not to exceed 1% by weight.
Water and Sediment (ASTM D-1796)
Not to exceed 0.1% by volume.
Carbon Residue (Ramsbottom ASTM D524 or Conradson, ASTM D-189)
Not to exceed 0.25% by weight on 10%
volume residue
Flash Point (ASTM D-93)
At least 52° C (125° F) or legal temperature
if higher than 52° C (125° F)
Density (ASTM D-287)
-1° C to 6° C (30° F to 42° F) API Gravity at
16° C (60° F) (0.816 to 0.876 Sp. Gr.)
Cloud Point (ASTM D-97)
6° C (10° F) below lowest ambient
temperature at which the fuel is expected to
operate.
Active Sulfur
Copper strip corrosion not to exceed No. 2
rating after 3 hours at 49° C (122° F)
Ash (ASTM D-482)
Not to exceed 0.02% by weight
Distillation (ASTM D-86)
The distillation curve must be smooth and
continuous. At least 90% of the fuel must
evaporate at less than 360° C (680° F). All
of the fuel must evaporate at 385° C
(725° F).
8-5
Section 8
HAZARDOUS SUBSTANCE PRECAUTION
!
WARNING
Hazardous Substance Precaution
Obey the precautions listed on the following table.
Failure to comply could result in serious injury, chronic health problems
and even reproductive system damage.
The following information is provided to assist the owners and operators of Ingersoll-Rand
Machinery Equipment. Further information may be obtained by contacting your Ingersoll-Rand
Road Machinery Equipment Distributor.
Table 8-3: Hazardous Substance Precaution
SUBSTANCE
8-6
PRECAUTION
Anti-Freeze
Avoid ingestion, skin contact and breathing fumes
Hydraulic Oil
Engine Lubrication Oil
Preservation Grease
Rust Preventative
Engine Fuel
Battery Electrolyte
SAE Gear Oil
Engine Exhaust Fumes
Avoid breathing and buildup of fumes in confined spaces
Electric Motor Dust
(Brushes/Insulation)
Avoid breathing during maintenance
SECTION 9 - SCHEMATICS
9-1
SECTION 9
SCHEMATICS
General Information
Additional full-size copies of the schematics are available by contacting the Ingersoll-Rand
Road Development Division. See your authorized Ingersoll-Rand dealer for assistance, if
required.
For ultimate machine life and maximum performance, we recommend the use of genuine
Ingersoll-Rand brand parts.
The electrical and hydraulic schematics included herein that are applicable to the PF-161
Paver are listed below.
Electrical Schematic
•
Electrical schematic, Drawing No. 15632664, page 9- 3.
Hydraulic Schematic
•
9-2
Hydraulic schematic, Drawing No. 15632672, page 9-4.
SCHEMATICS
SECTION 9
Electrical Schematic
CHECK
SWITCH
FILTER
-
POWER
87
86
85
s
+
30
RELAY
-
s
-
s
s
s
+
WATER TEMP
OIL TEMP
OIL PRESS
VOLTS
-
+
+
+
TACH
58
60 AMP
-
CONVERSION
CHART
0
.00
1/16
.06
1/8
.13
3/16
.19
1/4
.25
5/16
.31
3/8
.38
7/16
.44
1/2
.50
9/16
.56
5/8
.63
11/16
.69
3/4
.75
13/16
.81
7/8
.88
15/16
.94
1
1.00
PRESSURE
2D
40
41
42
30
START
85
RELAY
87
86
01
01
01
R
J
01
1
B
2B
2B
2
STARTER
22
J
22
ALTERNATOR
2C
A
2C
B
C
2D
167L
RH
FLOWGATE
*
AUTO
AUGER
MAN
MAN
AUTO
LH
FLOWGATE
TRUCK
HITCH
PIVOT
STEER
AUGER
H
J
RH
K
M
07
167R
37
170A
12
A
38
11
B
36
C
5
2E
D
24
09
E
27
F
G
26
25
24
16
15
9
28
9
38
9
39
37
36
OUT
IN
F.R.S. FAN
FWA ON/OFF
RH AUGER
CONV.
50
33L
02D
33H
170A
BRAKE
MOTOR HI/LO
H
AUGER UP
AUGER DOWN
SCREED UP
THROTTLE HI
TRACTION
POSITIVE
15 AMP
SCREED DOWN
168
20
02C
G
39
20
01
02B
F
LH AUGER
CONV.
DOWN
UP
LH
DOWN
LEFT
SHIFT
48
HORN
BRAKE
UP
DOWN
UP
DOWN
TRANS
HI
50
E
13
23
01
15 AMP
*
21
HOPPER UP
15 AMP
UP
DOWN
31
32
22
2D
02A
*
LO
2B
VIBRATOR
THROTTLE
01
2C
DOWN
*
33H
HOPPER DOWN
ENGINE SHUT
06
*
VIBRATOR
15 AMP
NUETRAL
START
MICRO SWITCH
MAIN
*
UP
*
01
10
POS. TRAC.
15 AMP
RIGHT
START
BRAKE
LIGHT
FWA
10A
AUGER
06A
SCREED
HOPPER
D
15
2E
15 AMP
87
30
MATERIAL
LOW
15 AMP
IN MOTION
86
MERCURY
SWITCHES
87
87A
86
30
85
50
ON
FLOWGATES
87
87A
86
FUEL
15 AMP
W
W
87
85
30
85
RH FLOWGATE
87
30
86
85
BLACK SIGNAL
COND.
GREEN
87
30
86
85
BLACK SIGNAL
COND.
GREEN
RED
RED
WHITE
WHITE
26
26A
30
86
25 AMP
LH FLOWGATE
86
87
85
15 AMP
MICRO SWITCH
ON CONTROL
HANDLE
B RH
SENSOR
G PLUG
R
33L
30
87
87A
86
85
85
87
30
30
B LH
SENSOR
G PLUG
R
85
86
22
PUMP
08
ES15632664_0101
9-3
SECTION 9
SCHEMATICS
Hydraulic Schematic
350 PSI
A
A
5075 PSI
4.92 CI/REV
1.04 CI/REV
5075 PSI
2.9 CI/REV
350 PSI
HAND PUMP
800
PSI
T
4.92 CI/REV
1.04 CI/REV
COOLER
.09375 ø
S
100
COOLER
BYPASS
FRONT WHEEL ASSIST
P
IN
CASE FLUSHING PROVIDED
BY DIFFERENTIAL PRESSURE
BETWEEN PRESSURIZED (5 PSI)
AND NON-PRESSURIZED SIDES
OF HYDRAULIC TANK.
5 PSI
PLANTETARY 53.3:1
189 PSI BRAKE RELEASE
A
5075 PSI
2.4 CI/REV
5.5 GPM
30 PSI
1.71
CI/REV
2.9 CI/REV
S
100
350 PSI
5075 PSI
SCREED LIFT
CYLINDER
P
350 PSI
1.03
CI/
REV
OUT
1/16 ø
B
A
SCREED
EXTENSION
CYLINDERS
1200-1800 PSI
5.5
36.6 CI/REV
BRAKE
.039 ø
1/16 ø
36.6 CI/REV
GB
B
.039 ø
F
SCREED LIFT
CYLINDER
00112-772-00
PLANETARY 53.3 :1
189 PSI BRAKE RELEASE
B
2.4 CI/REV
.37 IN /REV
P
T
V
FUME RECOVERY SYSTEM
T
SCREED
VALVE
SCREED
1.03
CI/
REV
1.71
CI/REV
AUGER/CONVEYOR CIRCUIT
TRACTION CIRCUIT
B
T
V
F
5.5
F
VIBRATOR
25
HYDRAULIC
MOTORS
AUX2
X
6 GPM
BY DIFFERENTIAL PRESSURE
THROTTLE LO
MOTOR HI
THROTTLE HI
.024ø
.024 ø
.5 GPM
SCREED
850PSI
AUX1
1800
PSI
CASE FLUSHING PROVIDED
BETWEEN PRESSURIZED (5 PSI)
AND NON-PRESSURIZED SIDES
OF HYDRAULIC TANK.
CONVERSION
CHART
0
.00
1/16
.06
1/8
.13
3/16
.19
1/4
.25
5/16
.31
3/8
.38
7/16
.44
1/2
.50
9/16
.56
5/8
.63
11/16
.69
3/4
.75
13/16
.81
7/8
.88
15/16
.94
1
1.00
9-4
2.9
CI/REV
BLAW KONTROL
6 GPM
S
100
PG X
STEER
VIBRATOR
HOPPER
UP
HOPPER
DOWN
TANK
SCREED
LIFT
X
AUGER
DOWN
AUGER
UP
CHARGE PRESSURE
TRUCK HITCH
(OPTIONAL)
X
CG
THROTTLE
AUGER LIFT
MAIN VALVE
'P'
'R'
'L'
'T'
'P'
'T'
'R'
STEERING CIRCUIT
'L'
HOPPER
GENERAL HYDRAULIC CIRCUIT
PRESSURIZED
NON-PRESSURIZED
HYDRAULIC RESERVOIR TYPES
HYD15632672_0001
SECTION 10 - RECOMMENDED
SERVICE PARTS
10-1
PF-161
SECTION 10 - RECOMMENDED SERVICE
Recommended Service Parts
Assembly
Description
1000
Hrs
2000
Hrs
3000
Hrs
CPN
1
15624828
Push Rollers
Push Roller
Roller
2
21057864
Shaft
2
20962239
Bearing
4
20930848
Hopper
Corner Overflow Guard
1
21141585
Center Overflow Guard
1
21141577
Hinge Tube
Hinge Rod
1
1
Hopper/Screed Lift Cylinder
20233979
20290722
1
20304218
Flow Gates
RH Flow Gate Plate
1
21141528
LH Flow Gate Plate
1
21141502
Jack (Power Flow Gate Assembly)
1
20946851
Conveyor
Conveyor Chain Assembly
2
20938908
Conveyor Chain Connecting Pin
2
20938916
Conveyor Chain Cotter Pin
2
20938924
Drag Bar
2
20349759
2
20939229
Conveyor Chain Repair Kit
Idler Shaft
1
21140850
Bearing
1
21443767
LH Front Chain Guard
1
21140900
RH Front Chain Guard
1
21140918
LH Rear Chain Guard
1
21140777
RH Rear Chain Guard
1
21140785
LH Rear Floor Plate
1
21140736
RH Rear Floor Plate
1
21140744
Center Floor Plate
1
21140751
Front Floor Plate
1
21140769
Auger / Conveyor Drive
Roller Chain
10-2
1
15502842
Outer Conveyor Bearing
1
20931747
Inner Conveyor Bearing
1
20292165
Auger Drive Sprocket
1
21140975
SECTION 10 - RECOMMENDED SERVICE PARTS
Assembly
Description
PF-161
1000
Hrs
2000
Hrs
Conveyor Drive Sprocket
1
Sprocket
1
3000
Hrs
CPN
21058888
21140975
Housing
1
15622681
Auger/Conveyor Drive Pump
1
20292330
Auger/Conveyor Drive Pump Filter
1
1
20926036
Auger/Conveyor Planetary Drive
1
20924262
Auger/Conveyor Drive Motor (Eff. With S/N
16128-01)
1
20928982
Auger/Conveyor Drive Motor (Prior to
16128-01)
1
20929857
Auger
LH Kick-in Auger Section
1
20955274
RH Kick-in Auger Section
1
20955282
LH Long Auger Section
1
20954988
RH Long Auger Section
1
20955001
LH Short Auger Section
1
20954996
RH Short Auger Section
1
20955019
LH Kick-out Auger Section
1
20206421
RH Kick-out Auger Section
1
20206439
LH Auger Section, Extension
1
20954988
RH Auger Section, Extension
1
20955001
Outer Auger Extension Support Bearing
1
20292157
Inner Auger Bearing
1
20292165
Feed Control
Paddle
1
21079926
Wire
1
20308193
Plug
1
20933560
Insulated Terminal
1
20940789
Traction Drive Pump
1
15497035
Traction Drive Motor (Eff. With S/N 1613001)
1
20329892
Traction Drive Motor (Eff. S/N 16126-01 to
16130-01)
1
20304804
Traction Drive Motor (Prior to S/N 1612601)
1
20930103
Traction Drive Planetary (Eff. With S/N
16130-01)
1
20327243
Traction Drive Planetary (Eff. S/N 16126-01
to 16130-01)
1
13784087
Traction Drive
10-3
PF-161
Assembly
Description
1000
Hrs
2000
Hrs
Traction Drive Planetary (Prior to S/N
16126-01)
3000
Hrs
CPN
1
20924312
20942629
Bogie Steering
Solid Tire
1
1
1
1
20986360
1
1
1
20930996
Wheel
Bearing Assembly
Bearing Cup
1
20930327
Bearing Cone
1
20930715
Tie Rod
1
21140637
Engine
John Deere 4039T Diesel
Oil Filter Element
2
2
2
20937710
Fuel Filter Element
2
2
2
20937728
Air Filter Element
1
1
1
20937884
Fan/Alternator Belt Matched Set
1
20300794
Alternator
1
20359659
Starter
1
13547989
Radiator Cap
1
1
1
20937777
Air Cleaner Element
1
1
1
20937884
Oil Filter Element
2
2
2
20289153
Fuel Filter Element
2
2
2
20289161
1
20289179
Alternator
1
13788013
John Deere 4045T Diesel
Starter
1
13788021
Radiator Cap
1
1
1
20937777
Air Cleaner Element
1
1
1
20937884
Oil Filter Element
2
2
2
21439419
Primary Fuel Element
2
2
2
21439385
Secondary Fuel Element
2
2
2
21439393
1
21439401
Alternator
1
13787908
Starter
1
20937793
Cummins 4BTA (Prior to S/N 16115-10)
Air Cleaner Element
1
1
1
20937884
Radiator Cap
1
1
1
20937777
Strainer Fuel Filter
2
2
2
21443825
Primary Fuel Filter
2
2
2
20163150
Cummins 4BTA (Eff. S/N 16115-10)
10-4
Assembly
PF-161
2000
Hrs
3000
Hrs
CPN
2
2
21439419
1
20259099
Alternator
1
13787908
Starter
1
13366620
Description
Oil Filter
1000
Hrs
2
Radiator Cap
1
1
1
20937777
Hydraulic Tank Filter Element
1
1
1
20925756
Hydraulic Filter Lip Gasket
1
1
1
20925806
General Purpose Pump
1
20928842
Main Control Valve
1
20929253
Power Steering Unit (Eff. With S/N 1610501)
1
20930160
Power Steering Unit (Prior to S/N 1610501)
1
20925061
Steering Cylinder
1
20926739
Hydraulics
Auger Lift Cylinder
1
20929675
Throttle Cylinder (Eff. With S/N 16104-01)
1
20929030
Throttle Cylinder (Prior to S/N 16104-01)
1
20929741
Brake/Release and Shift Valve (Eff. With S/
N 16130-01)
1
20329884
Brake/Release and Shift Valve (Prior to S/N
16130-01)
1
20177606
Side Arm Cylinder
1
20924742
Pump Control Fluid Filter
1
20929535
Electrical
Circuit Breaker, 30 Amp
1
1
1
20190682
Circuit Breaker, 20 Amp
1
1
1
20933503
Relay
1
1
1
20934592
Relay
1
1
1
20161055
1
20933974
1
20928149
1
20191003
Actuator for CPN 20934212 Switch
Operator Platform
Screed Heater & Washdown System Filter
1
1
Arm Rest Cover/Bottom Cushion Cover
Back Cushion Cover
1
20190997
Switch, 3 Position, 6 Terminal
1
20934195
Limit Switch
2
20934212
Switch, 3 Position, 3 Terminal
2
20934501
Kits
PF-161 Decal Kit
Hopper/Screed Lift Cylinder Seal Kit
1
TBD
1
20924494
10-5
PF-161
Assembly
3000
Hrs
CPN
Traction Drive Motor Seal Kit
1
59019679
Traction Drive Planetary Seal Kit (Eff. S/N
16130-01)
1
20311122
Traction Drive Planetary Seal Kit (Eff. S/N
16128-06 to 16130-01)
1
13784020
Traction Drive Planetary Seal Kit (Prior to S/
N 16128-06)
1
20924338
General Purpose Pump Repair Kit
1
20925608
Auger/Conveyor Drive Pump Seal Kit
1
20926127
Auger/Conveyor Drive Motor Seal Kit
1
20926218
Description
1000
Hrs
2000
Hrs
Auger/Conveyor Planetary Drive Gear Kit
1
20924288
Vibrator Motor Repair Kit
1
20926390
Throttle Cylinder Seal Kit
1
20176608
Power Steering Unit Seal Kit (Eff. With S/N
16105-01)
1
20376349
Power Steering Unit Seal Kit (Prior to S/N
16105-01)
1
20195327
Side Arm Cylinder Seal Kit
1
15493612
Steering, Auger Lift Cylinder Seal Kit
2
20924494
Journal & Bearing Repair Kit
1
20960373
Optional Equipment
Truck Hitch Assembly
Push Roller
2
21057864
Bearing
2
20930848
Shaft
2
Side Roller Assembly
20962239
2
20217782
Side Roller
2
20262655
Side Roller Shaft
2
20218004
Truck Hitch Cylinder
1
20174561
Truck Hitch Cylinder Seal Kit
1
20926952
Pivot Pin
1
20262663
Pivot Pin Bearing
1
20931036
Offset Arm
1
Truck Hitch Control Valve
20218251
1
20176848
Jack Assembly
1
20986006
Jack Repair Kit
1
20946752
Side Arm Guide Roller
1
21062559
Automatic Level Control Assembly/Tow
Point Control
10-6
LH Automatic Level Control Valve
1
15580996
RH Automatic Level Control Valve
1
15581002
Assembly
PF-161
1000
Hrs
Description
2000
Hrs
Side Arm Cylinder
3000
Hrs
CPN
1
20924742
Electric Flow Gate
Actuator
1
20946851
RH Flow Gate Plate
1
15584477
LH Flow Gate Plate
1
15584436
Front Wheel Assist Valve
1
20929956
Front Wheel Assist Motor
1
20929758
Seal Kit
1
20929766
Front Wheel Assist
LUBRICANTS
1 Qt.
1 Gal.
5 Gal.
55 Gal.
IR All-Season Premium Hydraulic Oil
n/a
n/a
59045179
59045187
IR Multi-Purpose Premium Engine Oil
59022343
59023507
57022327
59022335
IR Premium Limited-Slip Component Lubricant
13248455
13248463
59022418
59022426
IR Premium Multi-Purpose ATF
13248471
13248489
59023572
59023580
IR Synthetic Component Lubricant
13248430
13248448
59877597
59022459
IR Synthetic Plus Component Lubricant
13248414
13248422
59046177
59046165
10-7
10-8
WORD INDEX
NUMERIC
3-Position Function Toggle Switch ...................................................................................................................... 3-14
-AAdditional Operator’s Umbrella Option .................................................................................................................. 17
Adjustment of Hopper Side Extensions - As Required ....................................................................................... 5-70
Adjustment of Hopper Wiper Bars - As Required ............................................................................................... 5-68
Adjustment of Steering Consoles and Seats - As Required ............................................................................... 5-69
Adjustment of Swing Console - As Required ...................................................................................................... 5-68
Air Cleaner - Check/Change ............................................................................................................................... 5-41
Alarms Indications and Remedies ........................................................................................................................ 6-4
Alternate Ramp Method ........................................................................................................................................ 1-6
Annual Lubrication and Service .......................................................................................................................... 5-17
Annual Maintenance Requirements .................................................................................................................... 5-17
ANNUAL MAINTENANCE TASKS ..................................................................................................................... 5-58
Approved Lubricants ........................................................................................................................................... 5-14
ASSEMBLY ........................................................................................................................................................... 2-2
Auger Bearings - Grease .................................................................................................................................... 5-21
Auger Control Switch ............................................................................................................................................ 3-8
Auger Extension Switch .............................................................................................................................3-18, 3-20
Auger Override Toggle Switch ...................................................................................................................3-18, 3-20
Auger Section - Inspection and Replacement ..................................................................................................... 5-48
Auger Specifications ................................................................................................................................................ 9
Auger Speed Control Knob ........................................................................................................................3-18, 3-20
Auger/Conveyor Drive Chains - Check/Adjust .................................................................................................... 5-47
Auger/Conveyor Planetaries - Change Fluid ...................................................................................................... 5-61
AUGERS .................................................................................................................................................................. 9
AUTOMATIC FEED CONTROL SYSTEM ............................................................................................................. 10
Automatic Level Control ......................................................................................................................................... 17
-BBattery Gauge ....................................................................................................................................................... 3-6
BE AWARE OF SAFETY INFORMATION ............................................................................................................ 1-2
Before you Begin .................................................................................................................................................. 2-2
BERM ATTACHMENT OPTION ............................................................................................................................ 15
Blaw Kontrol® Ultrasonic Grade Control System Troubleshooting ....................................................................... 6-6
Blaw-Kontrol® Malfunction Remedy Table ........................................................................................................... 6-6
Blaw-Kontroll® II Option ......................................................................................................................................... 16
Brake Engaged Indicator ...................................................................................................................................... 3-5
Brake Release Hand Pump ................................................................................................................................ 3-12
Brake Release Hand Valve ................................................................................................................................. 3-11
BRAKES .................................................................................................................................................................. 6
-CChanging a Canister - Type Fuel Filter ............................................................................................................... 5-63
Changing a Spin-On-Type Fuel Filter ................................................................................................................. 5-65
Changing Hydraulic Oil Filters ............................................................................................................................ 5-53
Changing Hydraulic System Charge Filter .......................................................................................................... 5-56
Check Engine Indicator ......................................................................................................................................... 3-5
CLEAN UP AND WASHDOWN ............................................................................................................................ 5-6
CONTROLS ........................................................................................................................................................... 11
Conveyor Chains - Inspect/Adjust ....................................................................................................................... 5-29
CONVEYORS .......................................................................................................................................................... 9
Cooling Fan - Inspect .......................................................................................................................................... 5-26
COOLING SYSTEM ................................................................................................................................................. 6
Crankcase Breather Tube - Inspect .................................................................................................................... 5-28
W-1
WORD INDEX
-DDaily Lubrication and Service ............................................................................................................................. 5-15
Daily Maintenance Requirements ....................................................................................................................... 5-15
Daily Maintenance Tasks .................................................................................................................................... 5-19
DIESEL FUEL SPECIFICATIONS ........................................................................................................................ 8-5
DIESEL HEATERS WITH AUTOMATIC TEMPERATURE .................................................................................... 13
DIESEL ONLY HEATERS ..................................................................................................................................... 12
DIRECTION-SPEED CONTROL LEVERS ........................................................................................................... 3-2
Draining the Hydraulic System ............................................................................................................................ 5-50
Drive Belts - Inspect ............................................................................................................................................ 5-28
Drive Tire Servicing and Hydroinflation - As Required ........................................................................................ 5-70
Drive Wheel Planetaries - Change fluid .............................................................................................................. 5-62
DUAL FEED SYSTEMS ........................................................................................................................................... 8
-EELECTRICAL SCHEMATIC................................................................................................................................... 9-3
ELECTRICAL SYSTEM ........................................................................................................................................... 5
Empty Tunnel Indicator ......................................................................................................................................... 3-5
ENGINE ................................................................................................................................................................... 5
Engine Air Intake Piping - Inspect ....................................................................................................................... 5-27
Engine Coolant - Check ...................................................................................................................................... 5-57
Engine Fuel Filter - Change ................................................................................................................................ 5-63
Engine Kill Button .................................................................................................................................................. 3-7
ENGINE LUBRICATING OIL SPECIFICATIONS ................................................................................................. 8-4
Engine Oil - Check Level .................................................................................................................................... 5-23
Engine Oil and Filter - Change ............................................................................................................................ 5-38
Engine Radiator - Check Level ........................................................................................................................... 5-24
Engine Tachometer/Hour Meter ............................................................................................................................ 3-3
Environmental Specifications ................................................................................................................................ 7-2
Extension Fuel Pump Switch .....................................................................................................................3-18, 3-19
Extension Heater Igniter Switch .................................................................................................................3-18, 3-20
Extension Slope Toggle Switch .................................................................................................................3-17, 3-20
-FFloating Beam Reference Option ........................................................................................................................... 17
Flow Gate Position Indicators ............................................................................................................................. 3-13
FLUID CAPACITIES ............................................................................................................................................. 8-3
Front Bogie Wheels - Repack ............................................................................................................................. 5-59
Front Conveyor Bearing - Grease ....................................................................................................................... 5-20
FRONT SUSPENSION ............................................................................................................................................ 7
Front Wheel Assist Switch .................................................................................................................................... 3-6
Front Wheel Bogie Pivot Bearings - Grease ....................................................................................................... 5-35
Front Wheel King Pins - Grease ......................................................................................................................... 5-34
Front Wheel Power Assist Option .......................................................................................................................... 16
FUEL AND LUBRICANT SPECIFICATIONS ........................................................................................................ 8-2
Fuel Pump - Check ............................................................................................................................................. 5-46
Fuel Pump Switch ............................................................................................................................................... 3-20
FUEL SYSTEM ........................................................................................................................................................ 6
Fuel Water Separator - Drain .............................................................................................................................. 5-28
W-2
WORD INDEX
-G-
GENERAL ................................................................................................................. 1-3, 2-2, 4-2, 5-2, 6-2, 7-2, 8-2
GENERAL ASSEMBLY ........................................................................................................................................ 2-2
GENERAL EQUIPMENT OPTIONS ...................................................................................................................... 16
General Fault Isolation Tips/Information ............................................................................................................... 6-2
GENERAL INFORMATION ...................................................................................................................................... 4
General Troubleshooting Guidelines .................................................................................................................... 6-3
Governor Switch ................................................................................................................................................. 3-10
-H-
HAZARDOUS SUBSTANCE PRECAUTION ...............................................................................................1-12, 8-6
Hopper Control Switch .......................................................................................................................................... 3-9
Hopper Hinge Assembly - Inspection/Repair ...................................................................................................... 5-48
Horn Button ........................................................................................................................................................... 3-9
How This Section Works ....................................................................................................................................... 6-3
Hydraulic Filter Light ............................................................................................................................................. 3-6
Hydraulic Fluid - Check Level ............................................................................................................................. 5-21
Hydraulic Fluid and Filters - Change ................................................................................................................... 5-49
HYDRAULIC OIL REQUIREMENTS AND SPECIFICATIONS ............................................................................. 8-3
HYDRAULIC SCHEMATIC .................................................................................................................................... 9-4
HYDRAULIC SCREED EXTENSIONS .................................................................................................................. 14
HYDRAULIC SYSTEM ............................................................................................................................................ 6
-IIDENTIFICATION DATA .......................................................................................................................................... 3
IDENTIFICATION OF MAJOR COMPONENTS .................................................................................................... 18
IGNITION CONTROL (ATIC) ................................................................................................................................. 13
Initial Screed Angle-of-Attack ................................................................................................................................ 4-5
Initial Screed Elevation ......................................................................................................................................... 4-4
Installation of 1-foot Bolt-on Screed Extension ................................................................................................... 2-21
Installation of Additional Augers .......................................................................................................................... 2-15
Installation of the 18-inch Tapered-Joint Extension ............................................................................................ 2-24
Installation of the 8-foot Wedge-lock Screed ...................................................................................................... 2-26
Installation of the Ags (7.5) Controllers ............................................................................................................... 2-31
Installation of the Automatic Feed Control Sensors ............................................................................................ 2-10
Installation of the Cut-off Plate ............................................................................................................................ 2-14
Installation of the Edger-plate Assemblies ............................................................................................................ 2-8
Installation of the Paddle Sensors ...................................................................................................................... 2-10
Installation of the Steering Guide .......................................................................................................................... 2-7
Installation of Ultra 3s Ultra Sonic Sensors ......................................................................................................... 2-12
Installation of Ultrasonic 4 Sonic Averaging System/Sonic Joint Matcher .......................................................... 2-28
INTRODUCTION ..................................................................................................................................................... 2
-JJog Toggle Switch ............................................................................................................................................... 3-14
W-3
WORD INDEX
-LLCD ..................................................................................................................................................................... 3-16
LH and RH Flow Gate Control Toggle Switches ................................................................................................. 3-17
LH Control Panel ................................................................................................................................................. 3-17
LH Flowgate Control Switch .................................................................................................................................. 3-8
Lighting the Screed Heater ................................................................................................................................... 4-5
LOADING AND UNLOADING ............................................................................................................................... 1-6
Loading Dock with Ramp (Preferred Method) ....................................................................................................... 1-6
Lubricants ........................................................................................................................................................... 5-13
LUBRICATING OIL/GREASE (EXCEPT ENGINE) .............................................................................................. 8-4
LUBRICATION AND SERVICE SCHEDULE ...................................................................................................... 5-14
-MMACHINE DESCRIPTION ....................................................................................................................................... 4
MACHINE IDENTIFICATION ................................................................................................................................... 3
Machine Identification ........................................................................................................................................... 7-2
Machine Identification Data ...................................................................................................................................... 3
MAIN CONTROL PANEL ...................................................................................................................................... 3-3
Main Fuel Pump Power Switch ..................................................................................................................3-18, 3-21
Main Igniter Power Switch .........................................................................................................................3-18, 3-21
Maintenance ....................................................................................................................................................... 1-10
Maintenance Indicator ........................................................................................................................................... 3-3
MAINTENANCE INSTRUCTIONS ...............................................................................................................5-2, 5-19
Malfunction Remedy Table ................................................................................................................................... 6-4
MANDATORY SAFETY MEASURES ................................................................................................................... 1-5
MAT KONTROL® II WITH PADDLE SENSORS ................................................................................................... 10
MAT KONTROL® II WITH ULTRA 3s® SENSORS .............................................................................................. 10
Mat Reference Option ............................................................................................................................................ 17
Material Indicator (Option) .................................................................................................................................. 3-12
Material Indicator Kit Option ................................................................................................................................... 16
MISCELLANEOUS MAINTENANCE TASKS ..................................................................................................... 5-67
Miscellaneous Maintenance Tasks ..................................................................................................................... 5-18
Miscellaneous Specifications ................................................................................................................................ 7-4
Mode Switch ....................................................................................................................................................... 3-15
Monthly Maintenance Requirements .................................................................................................................. 5-16
Monthly Maintenance Tasks ............................................................................................................................... 5-35
Motor Shift Switch ................................................................................................................................................. 3-8
MOVING THE MACHINE - UNDER PROPULSION ........................................................................................... 4-11
MOVING THE MACHINE BETWEEN WORKSITES .......................................................................................... 4-15
Muffler Installation ............................................................................................................................................... 2-14
-OOFF SEASON STORAGE .................................................................................................................................. 5-70
Oil Pressure Gauge .............................................................................................................................................. 3-5
Oil Temperature Gauge ........................................................................................................................................ 3-6
OMNISCREED® IA ................................................................................................................................................ 15
OMNISCREED® Specifications ............................................................................................................................. 15
Operating .............................................................................................................................................................. 1-9
OPERATING CONTROLS AND INSTRUMENTS ................................................................................................ 3-2
OPERATING INSTRUCTIONS ............................................................................................................................. 4-2
OPERATING THE MACHINE - GENERAL GUIDELINES .................................................................................. 4-10
OPERATOR’S UMBRELLA ..................................................................................................................................... 7
OPTIONAL INSTALLATION GUIDELINES ........................................................................................................ 2-14
ORGANIZATIONAL MEASURES ......................................................................................................................... 1-4
OVERVIEW ........................................................................................................................................................... 1-3
W-4
WORD INDEX
-PParking Brake - Operational Check .................................................................................................................... 5-35
Parking Brake Switch .......................................................................................................................................... 3-10
Perform the steps below to install the system ..................................................................................................... 2-29
Perform the steps outlined below to adjust the conveyors .................................................................................. 5-30
PERIODIC MAINTENANCE ............................................................................................................................... 5-13
Physical Specifications ......................................................................................................................................... 7-2
Pivot Steer Switch ............................................................................................................................................... 3-11
PIVOT STEERING ................................................................................................................................................... 7
Positioning the Machine and its Controls .............................................................................................................. 4-4
Positioning the Material Truck and Starting to Pave ............................................................................................. 4-8
Positive Traction Switch ...................................................................................................................................... 3-10
POWER FLOW GATES ........................................................................................................................................... 8
POWER SLOPE OPTION FOR 2.5/5B HYDRAULIC EXTENSIONS .................................................................... 14
Pre-Start Checks and Verifications ....................................................................................................................... 4-2
PRE-START INSPECTION ................................................................................................................................... 1-6
Preventative Maintenance Checklist ................................................................................................................... 5-18
PROCEDURE WHEN RECEIVING THE MACHINE ............................................................................................... 2
PROPANE (LPG) HEATERS WITH ATIC ............................................................................................................. 13
Pump Drive Box - Change Fluid ......................................................................................................................... 5-59
-QQuarterly Lubrication and Service ....................................................................................................................... 5-16
Quarterly Maintenance Requirements ................................................................................................................ 5-16
QUARTERLY MAINTENANCE TASKS .............................................................................................................. 5-38
-RRadiator Hoses - Check ...................................................................................................................................... 5-46
RECOMMENDED SERVICE PARTS .................................................................................................................. 10-1
Rear Control Stations .......................................................................................................................................... 3-13
Rear Conveyor Bearings - Grease ...................................................................................................................... 5-20
REAR SUSPENSION .............................................................................................................................................. 7
Refilling Hydraulic System with Fluid .................................................................................................................. 5-57
Removal and Cleaning of Relief (In Hydraulic Tank) .......................................................................................... 5-54
RH and LH Conveyor Switches ............................................................................................................................ 3-9
RH Control Panel ................................................................................................................................................ 3-19
RH Flowgate Control Switch ................................................................................................................................. 3-8
-SSAFETY ................................................................................................................................................................ 1-2
SAFETY INSTRUCTIONS GOVERNING OPERATION ....................................................................................... 1-7
SCHEMATIC, ELECTRICAL.................................................................................................................................. 9-3
SCHEMATIC, HYDRAULIC ................................................................................................................................... 9-4
SCREED CHOICES/SCREED OPTIONS ............................................................................................................. 12
Screed Control Panels ........................................................................................................................................ 3-16
Screed Control Switch .......................................................................................................................................... 3-8
Screed Depth Cranks - Grease ........................................................................................................................... 5-32
Screed Extension In/Out Toggle Switch ....................................................................................................3-19, 3-20
SCREED HEATERS .............................................................................................................................................. 12
Screed Pivot Points - Grease .............................................................................................................................. 5-33
Screed Vibrator Shaft Bearings - Grease ........................................................................................................... 5-21
Screed Vibrator Switch ....................................................................................................................................... 3-10
Securing the Machine to the Transporter (Tiedown) ........................................................................................... 4-15
Selecting a Site for Assembly ............................................................................................................................... 2-3
SELECTION AND QUALIFICATION OF PERSONNEL ....................................................................................... 1-4
Selector Switch ................................................................................................................................................... 3-16
W-5
WORD INDEX
Semi-Annual Lubrication and Service ................................................................................................................. 5-17
Semi-Annual Maintenance Requirements .......................................................................................................... 5-17
SEMI-ANNUAL MAINTENANCE TASKS ........................................................................................................... 5-49
Short-Coupled Drive Shaft - Grease ................................................................................................................... 5-46
Slope/Grade Controller ....................................................................................................................................... 3-15
SMOKEEATER® VENTILATION CONTROL SYSTEM ........................................................................................ 10
Starter Button ........................................................................................................................................................ 3-7
Starting .................................................................................................................................................................. 1-8
Starting the Machine ............................................................................................................................................. 4-3
Steering Units ....................................................................................................................................................... 3-2
Stop Engine Indicator ............................................................................................................................................ 3-5
Stopping ................................................................................................................................................................ 1-9
Suggestions to Make Cleanup Easier ................................................................................................................... 4-3
-TTECHNICAL SPECIFICATION ............................................................................................................................. 7-2
Throttle Switch .................................................................................................................................................... 3-10
TOWING THE MACHINE ................................................................................................................................... 4-16
TRACTION DRIVE ................................................................................................................................................... 6
TRACTION LOCK SYSTEM .................................................................................................................................... 7
Transmission Shift Switch ..................................................................................................................................... 3-7
TROUBLESHOOTING .......................................................................................................................................... 6-2
TRUCK HITCH ......................................................................................................................................................... 7
Truck Hitch In/Out Button .................................................................................................................................... 3-11
Truck Hitch Option Rollers - Grease ................................................................................................................... 5-27
Truck Hitch Option Slides - Clean/Grease .......................................................................................................... 5-31
Truck Hitch Specifications ........................................................................................................................................ 7
-UUltraEye® V Grade Sensor Option ........................................................................................................................ 17
UNDERSTAND SIGNAL WORDS ........................................................................................................................ 1-2
Unloading the Machine ......................................................................................................................................... 2-3
Up/Down Indicators ............................................................................................................................................. 3-14
Up/Down Knob .................................................................................................................................................... 3-16
-VVentilation Control Switch ................................................................................................................................... 3-11
-WWait To Start Indicator .......................................................................................................................................... 3-3
Warning Indicator ................................................................................................................................................ 3-16
WARNING OF SPECIAL DANGERS .................................................................................................................. 1-13
WARNINGS .......................................................................................................................................................... 1-3
Washdown Fuel Filter - Change ......................................................................................................................... 5-66
WASHDOWN SYSTEM ......................................................................................................................................... 11
Water in Fuel Indicator .......................................................................................................................................... 3-4
Water Temperature Gauge ................................................................................................................................... 3-6
WEDGE-LOCK® SCREED .................................................................................................................................... 13
WEDGE-LOCK® SCREED EXTENSIONS ............................................................................................................ 14
Wedge-Lock® Screed Extensions Size and Options ............................................................................................. 14
Wedge-Lock® Screed Specifications ..................................................................................................................... 13
Weekly Lubrication and Service .......................................................................................................................... 5-16
Weekly Maintenance Requirements ................................................................................................................... 5-16
Weekly Maintenance Tasks ................................................................................................................................ 5-31
W-6
HIGHWAY CLASS PAVER WARRANTY
Ingersoll-Rand Company (“IR”) warrants to its and its affiliates’ authorized dealers, who in turn warrant to the
initial user only, that each new Ingersoll-Rand Highway Class Paver sold by the dealer will be free from
proven defects in material and workmanship for a period of twelve (12) months from the in service date to
the initial user or 1500 hours of service by the initial user, whichever occurs first.
During the warranty period, an authorized distributor shall repair or replace, at IR’s option, any part that is
found upon inspection to be defective in material or workmanship. Such part will be repaired or replaced
without charge for parts and labor to the initial user by an authorized dealer. The initial user shall provide the
authorized dealer with prompt notification of the defect and allow reasonable time for repair or replacement.
IR may require failed parts to be returned to the factory. Transportation of the product to the authorized
dealer is the responsibility of the user. The remedies provided in this warranty are exclusive.
This warranty does not apply to failures occurring as a result of abuse, misuse, negligent repairs, corrosion,
erosion and normal wear and tear, alterations or modifications made to the product without the express
written consent of IR, or failure to follow the recommended operating practices and maintenance procedures
as provided in the product’s operating and maintenance publications. This warranty does not cover
replacement of scheduled service items such as oil, filters, and wear items. This warranty does not apply to
engines (including engine electrical components) and tires or other accessories and equipment furnished by
IR, but manufactured by others. The initial user shall rely solely on the warranty, if any, of the respective
manufacturers thereof.
THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND CONDITIONS
(EXCEPT FOR THE WARRANTY OF TITLE), EXPRESS OR IMPLIED. IR DISCLAIMS ALL OTHER
WARRANTIES AND CONDITIONS, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES
OR CONDITIONS OF MERCHANTIBILITY OR FITNESS FOR A PARTICULAR PURPOSE.
IN NO EVENT SHALL IR OR ANY OF ITS AFFILIATES, SUBSIDIARIES OR AUTHORIZED DEALERS BE
LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHATSOEVER,
INCLUDING, BUT NOT LIMITED TO, LOSS OR INTERRUPTION OF BUSINESS, LOST PROFITS, OR
LOSS OF MACHINE USE, WHETHER BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE,
STRICT LIABILITY, STATUTE OR OTHERWISE, EVEN IF IR OR ANY OF ITS AFFILIATES,
SUBSIDIARIES OR AUTHORIZED DEALERS HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH
DAMAGES. THE TOTAL LIABILITY OF IR, ITS AFFILIATES, SUBSIDIARIES AND AUTHORIZED
DEALERS WITH RESPECT TO THE PRODUCT FURNISHED HEREUNDER SHALL NOT EXCEED THE
PURCHASE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS BASED, EXCEPT FOR
CLAIMS FOR PERSONAL INJURY.
The undersigned acknowledges that he/she has received a copy of this warranty on the
date set forth below.
Initial user:
By:
Title:
Date:
CPN: 13858246
(Name of company)
062105
Road Development
Ingersoll-Rand Company
312 Ingersoll Drive
Shippensburg,PA 17257
© 2005 Ingersoll-Rand Company
Printed in the U.S.A.

OPERATION AND MAINTENANCE MANUAL Ingersoll

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