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Blaw-Knox PF-200, Manual

The Blaw-Knox PF-200 user manual is a comprehensive guide to operating and maintaining this exceptional product. Available for free download from our website, it provides step-by-step instructions and valuable insights. Get all the details you need to maximize your experience with the Blaw-Knox PF-200 at manualshive.com.

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Drive Train

Highway Class Paver/Finishers

A-1

TABLE OF CONTENTS

TASK

PAGE NO.

Table of Contents ............................................................................................................... A-1
Alphabetical Index .............................................................................................................. A-2
Safety Precautions ............................................................................................................. A-3
Theory of Operation ............................................................................................................ A-4
System Maintenance and Service ...................................................................................... A-7
Drive Train Troubleshooting ............................................................................................... A-8
Engine Assembly .............................................................................................................. A-14
Radiator ............................................................................................................................ A-19
Water Temperature and Oil Pressure Sending Units ....................................................... A-22
Hour Meter Switch ............................................................................................................ A-24
Air Cleaner  Assembly ...................................................................................................... A-25
Exhaust Muffler ................................................................................................................. A-29
Throttle Cylinder ............................................................................................................... A-31
PTO and Clutch Assembly ............................................................................................... A-33
Pump Drive Transmission ................................................................................................ A-43
Three Speed Traction Transmission Assembly (Wheeled) .............................................. A-47
Three Speed Traction Transmission Assembly (Tracked) ............................................... A-51
Traction Drive Shaft Assembly ......................................................................................... A-56
Traction Drive Motor (see Hydraulics)
Drive Axle and Brake Assembly (Wheeled) ...................................................................... A-58
Electric Axle Shift Unit ...................................................................................................... A-62
Drive Wheel and Tire (Wheeled) ...................................................................................... A-64
Drive Wheel Spindle and Hub Assembly (Wheeled) ........................................................ A-68
Drive Chain and Tightener Assembly (Wheeled) ............................................................. A-72
Traction Case Assembly (Drop Box) (PF-510) ................................................................. A-75
Traction Drive Track Assembly (PF-510) ......................................................................... A-89
Track Band (PF-510) ........................................................................................................ A-95
Track Pad (PF-510) .......................................................................................................... A-99
Bogie Wheel Assembly (Wheeled) ................................................................................. A-103
Bogie Wheel Assembly (Tracked) .................................................................................. A-108
Take-Up Wheel Assembly (PF-510) ............................................................................... A-113
Front Wheel Assist (see Hydraulics)
Appendix A – Vendor Component Publications Listing .......................................... Appdx–A-1
Appendix B – Fabricated Tools .............................................................................. Appdx–B-1

Summary of Contents for PF-200

Page 1: ...bly Wheeled A 47 Three Speed Traction Transmission Assembly Tracked A 51 Traction Drive Shaft Assembly A 56 Traction Drive Motor see Hydraulics Drive Axle and Brake Assembly Wheeled A 58 Electric Axle Shift Unit A 62 Drive Wheel and Tire Wheeled A 64 Drive Wheel Spindle and Hub Assembly Wheeled A 68 Drive Chain and Tightener Assembly Wheeled A 72 Traction Case Assembly Drop Box PF 510 A 75 Tractio...

Page 2: ...A 64 Traction Drive Motor see Hydraulics Traction Drive Shaft Assembly A 56 Transmission Pump Drive A 43 Water Temperature and Oil Pressure Sending Units A 22 Wheel Assembly Bogie A 103 TRACKED PAVERS Air Cleaner Assembly A 25 Band Track PF 510 A 95 Bogie Wheel Assembly Tracked A 108 Case Assembly Traction Drop Box PF 510 A 75 Clutch and PTO Assembly A 33 Cylinder Throttle A 31 Electric Axle Shift...

Page 3: ...gents do intend to change demount or mount a tire ask a tire service store for complete instructions Not following correct procedures could result in faulty positioning of the tire and or rim parts causing serious physical injury or death WARNING Do not adjust traction drive chains when engine is operating Injury could result if machine moves CAUTION When bleeding brakes loosen bleeder plug approx...

Page 4: ...avers may have ON OFF pumps to separate conveyor drive 12 and auger drive 13 L H and R H motors The auger function of each feed system is driven by a single speed motor The conveyor speed on either or both sides can be changed from HI to LO speed in relation to the respec tive auger The auger motors are fixed displacement and the conveyor motors are dual displacement for HI LOW operation Mechanica...

Page 5: ...ummins or a John Deere 4 cylinder diesel engine 1 Power is delivered through a PTO clutch 2 and short coupled drive shaft 3 to a pump drive box 4 Traction drive power is hydrostatically transmitted from the variable displacement traction drive pump 5 to the fixed displacement traction drive motor 6 All early PF 171 s before ser 17111 01 PF 172 s before ser 17209 01 have EDC electric displace ment ...

Page 6: ...forward whenever the engine is running Cylinder pressure is maintained by the check valve when the engine is off During operation if slack is required in either track when going over large obstructions or passing solid materials through the drive sprocket and bogies the track tension cylinder retracts As pressure on the cylinder increases from an obstruction a hydrau lic relief valve will bypass h...

Page 7: ...one of the most important systems of the machine To ensure machine availability preven tive maintenance must be performed before work begins Preventive maintenance begins with inspection Systematic inspection may reveal damage that if not corrected may result in serious damage or failure Any problems revealed during pre service inspection must be reported to the shop foreman or service manager The...

Page 8: ...where the malfunction occurs and then locate the defective component DRIVE TRAIN TROUBLESHOOTING The troubleshooting guides in this section list the common malfunctions which may be found during the operation or maintenance of the machine You should perform the test inspections and corrective actions in the sequence listed This manual cannot list all malfunctions that may occur nor all tests or in...

Page 9: ...or starter motor connections Check starter connections Clean tighten 7 Open electrical circuit Check for wire off of any terminal in circuit Reconnect 8 Faulty neutral start limit switches Check position voltage continuity Reposition on traction pump or inside of op consoles switch es see number 1 or replace 9 Faulty starter motor solenoid Check voltage function Replace 10 Faulty starter relays on...

Page 10: ... or replace Check injectors injection fuel lines Clean 3 Contaminated fuel in tank Check tank Drain refill 4 Incorrect fuel in tank Check tank Drain refill 5 Slow cranking engine Cold weather Release clutch Check battery voltage Charge or replace Check battery electrolyte level Fill charge Check battery terminals Clean tighten 6 Other engine problems See Engine Manual See John Deere Engine Operato...

Page 11: ...ction pump s not stroking MDC machine only Check linkage Repair or replace Check MDC on pump s Repair or replace Check charge pressure Repair or replace 7 Traction pump not stroking EDC machines only Check manual override red plastic screw on pump EDC Check pump solenoid coil voltage continuity Replace Check voltage outputs of lever control s under load Replace control lever complete see elec sect...

Page 12: ...Repair MACHINE WILL NOT STEER PROPERLY WHEEL DRIVEN Problem Solution 1 One foot brake not released Check brake calipers on ends of axle Repair Check master cylinder Repair 2 Steering linkage not greased Check linkage below hopper Grease 3 Steering linkage bent or worn Check tie rods below hopper Straighten rods adjust or replace rod ends 4 Faulty steering unit s Try other operator s console Repair...

Page 13: ... consoles Check voltage continuity Replace 7 Faulty FWA switch on op consoles Check voltage continuity Replace 8 Inadequate charge pressure Check at pump Repair or replace pump PARKING BRAKE WILL NOT RELEASE Problem Solution 1 Brake does not release when switch is OFF Check manual override on control valve Check voltage continuity of control valve coil Replace coil 2 Clutch is not engaged Check cl...

Page 14: ...y Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Engine housing removed None None Battery disconnected Air cleaner assembly removed Machine blocked to prevent movement Catch container for oil 5 gal 20 L Catch container for coolant 10 gal 40 L Throttle cylinder removed ...

Page 15: ...t side of machine b Loosen radiator cap 2 2 0760 21B c Open radiator drain petcock 3 d Allow radiator coolant to drain into catch con tainer e After coolant has drained close radiator drain 3 1144 57 Step 3 Disconnect drive shaft a Remove drive shaft cover bolts b Remove drive shaft cover 4 4 0760 29A c Remove clutch side flange mounting bolts bolts have loctite on them from drive shaft 5 d For ac...

Page 16: ...nlet hose on top of oil cooler and remove hose 8 0718 97A e Mark plug and cap inlet hose and oil cooler fitting Step 5 Disconnect electrical wiring harness a Disconnect wires 9 from alternator 9 0760 34A b Cut tie straps holding wiring harness to engine c Remove clamps holding wiring harness to clutch housing d Disconnect wire on water temperature sensor 10 e Unplug fuel shut off wire 11 from engi...

Page 17: ... and return 16 lines a Loosen clamps on fuel lines b Pull fuel lines off of fittings 16 15 1144 71 Step 8 Remove engine a Secure chain to lifting eyes and attach to hoist Engine weighs approximately 500 lbs 230 kg Take up slack b Remove engine mounting bolts 17 on the right side by the oil drain 17 1144 72 c Remove mounting bolts on left side of engine on front and rear brackets 18 d Lift engine o...

Page 18: ...rocedures EQUIPMENT PREPARATION Step 1 Install throttle cylinder 19 on engine See THROTTLE CYLINDER for installation procedures 19 0760 40C Step 2 Install air cleaner assembly 20 on engine See AIR CLEANER ASSEMBLY for installation procedures 20 0760 20A Step 3 Fill engine with oil Step 4 Fill radiator with proper coolant mixture Step 5 Check hydraulic tank fluid level Step 6 Connect battery Step 7...

Page 19: ...n Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Engine housing raised Cooling system None Machine blocked to prevent movement Pressure tester Battery disconnected Coolant Catch container for coolant 10 gal 40 L ...

Page 20: ... a Loosen clamps on hoses 2 and 3 b Pull hoses off of radiator 2 3 0760 31A Step 3 Remove lower hose a Loosen clamp on hose 4 b Pull hose off of engine 4 1144 63 Step 4 Remove fan guard and shroud a Remove shroud mounting bolts b Pull shroud and fan guard 5 back 5 0760 50A Step 5 Remove radiator CAUTION Do not damage radiator during removal a Remove radiator mounting bolts b Attach lifting device ...

Page 21: ...sary Step 3 Remove radiator cap Step 4 Install pressure testing unit and radiator cap a Pump air into the system cap should relieve pressure at 7 psi 48 kpa 48 bar b If pressure on gauge begins to fall there is a leak in the radiator c Determine where leak is and repair or replace radiator BK 168 EQUIPMENT PREPARATION Step 1 Fill radiator with proper fluid mixture approx 26 qts 25 L PF 200 and PF5...

Page 22: ...al Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Battery disconnected None None Engine housing raised Machine blocked to prevent movement Note Refer to Electrical Section E for additional information ...

Page 23: ...3 Disconnect wire to oil pressure sending unit 2 2 0760 60C Step 4 Unscrew oil pressure sending unit from engine INSTALLATION Install the sending units by reversing removal proce dures EQUIPMENT PREPARATION Step 1 Connect battery Step 2 Start engine Make sure oil pressure and water temperature gauges on the center console LED are functioning correctly If the readings on the LED are incorrect refer...

Page 24: ... are wired directly to the tachometer as shown in the electrical schematic for your machine Other machines early and later models do not have this switch Signal wiring for hour meter comes from the main switch There are three different tachometer hour meter units used Early units as indicated above accumulated time whenever ignition switch was on Middle and later units accumulate time only with en...

Page 25: ...dure covers Removal Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Battery disconnected None None Machine blocked to prevent movement Engine housing raised ...

Page 26: ...B b Remove mounting bolts attaching air cleaner mounting bracket 2 to the engine just above the clutch and on the right side 2 1144 62 c Loosen hose clamp 3 and disconnect hose from engine 4 4 3 BK 169 d Lift entire air cleaner assembly with brackets out of machine DISASSEMBLY Step 1 Remove air cleaner cover a Loosen wing bolt 1 b Pull cover off 1 0760 64B ...

Page 27: ... 3 0738 13C Step 2 Inspect and clean air cleaner filter a Check for dirt b Blow out air cleaner with low pressure com pressed air Step 3 Clean out housing and cover a Wipe down inside of air cleaner housing 4 b Remove all dust collected 4 0738 13D Step 4 Clean out dust collector inside of cover a Loosen wing nut 5 on inside of cover b Remove dust collection cover 6 c Remove all dust collected in c...

Page 28: ...eaner housing cover IMPORTANT Always replace air cleaner housing cover with arrows pointing up This will keep the dust in the dust collection area a Make sure dust collection cover is in place b Place cover on housing with arrows pointing up c Make sure cover fits under clamp d Tighten wing bolt 1 1 0760 64B INSTALLATION Install the air cleaner by reversing removal procedures BK 170 ...

Page 29: ...rocedure covers Removal Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Engine shut off None None Machine blocked to prevent movement Muffler cooled ...

Page 30: ... functions properly EXHAUST MUFFLER CAUTION Muffler can be hot Make sure muffler is cool before attempting to remove it from the engine or wear protective gloves REMOVAL Step 1 Remove exhaust rain cap 1 or loosen elbow clamp and remove elbow 1 BK 48 Step 2 Remove muffler a Loosen muffler clamp 2 b Remove muffler 3 3 2 BK 49 NOTE If machine is positioned outside and a muffler is not being installed...

Page 31: ...ents Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Battery disconnected None None Machine blocked to prevent movement Engine hood raised Catch container for hydraulic fluid 3 qts 3 L Note Refer to Hydraulic Section D for additional information Refer to Engine Manual for additional Idle Adjustment information ...

Page 32: ...IDLE position Step 3 Adjust IDLE RPM a Loosen jam nut 5 b Adjust idle stop screw 6 for 1000 RPM c Tighten jam nut 1144 58B 5 6 Step 4 Adjust PAVE RPM a Set governor switch in PAVE position b Move throttle switch to FULL position Loosen jam nut 7 and adjust left end cylinder stop nut 8 for 1800 RPM Tighten jam nut to maintain setting 18 45 7 cm BK 17 8 10 7 9 Step 5 Adjust TRAVEL RPM a Set governor...

Page 33: ...dure covers Removal Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Front deck plates removed None None Battery disconnected Machine blocked to prevent movement ...

Page 34: ...lts from opposite end of drive shaft e Remove drive shaft from machine f Push manual clutch lever towards the clutch assembly to engage clutch once drive shaft is removed 3 4 2 0760 28B Step 2 Remove auger conveyor pumps 4 to improve access Step 3 Remove clutch housing a Remove the bolts that attach the clutch housing 5 to the engine 1144 61A 5 b Pull clutch housing away from the engine to disenga...

Page 35: ... 15 16 17 18 19 20 21 22 Driving ring Inspection plate Pilot bearing Drive shaft Shaft nut Lockwasher Clutch assembly Fork assembly Adjusting yoke Sliding sleeve Floating plate Hub and back plate Driving plate Clutch housing Shaft seal Retaining ring Bearing Bearing retaining ring Clutch lever shaft Clutch lever Lock pin Grease fitting 17 18 15 16 9 20 19 8 10 7 1 6 12 13 11 5 3 7 21 14 22 ...

Page 36: ...e entire clutch assembly 7 off the clutch shaft as a unit The clutch shaft and fork assembly 8 remain in the housing Step 7 Disengage lock pin 21 a Set clutch assembly upright and pull up on the lock pin away from the floating plate b Insert a small pin paper clip etc to hold lock pin up 0738 03 Step 8 Remove adjustment yoke 9 a Rotate sliding sleeve 10 and adjustment yoke assembly counterclockwis...

Page 37: ...uff keys d Remove the two woodruff keys from the operat ing shaft e Remove the operating shaft from the housing Step 14 OPTIONAL If further disassembly is required refer to Appendix A 1 for a listing of available clutch publications ASSEMBLY NOTE Assembly is performed outside of machine NOTE Refer to the exploded view of the PTO and clutch assembly as needed for assembly Step 1 OPTIONAL If further...

Page 38: ...ings in the recesses NOTE 3 pc driving plate s if equipped can be installed at a further point in the assembly process b If installing 1 pc driving plate 13 place it on the hub and back plate centering it to the hub Step 7 Install floating plate 11 a Place the floating plate onto the driving plate 1 pc plate Place plate on hub and back plate for 3 piece driving plate b Align the teeth with those o...

Page 39: ... to maintain this centered position c Remove driving ring from the driving plate CAUTION The clutch must remain engaged until the PTO and clutch assembly is installed back onto the engine Failure to do so will result in a lack of alignment of the driving plate teeth to the driving ring teeth making installation extremely difficult or damaging the teeth Step 11 Connect grease fitting 22 to the clut...

Page 40: ...haft into the pilot bearing c OPTIONAL Install two 3 8 x 3 pilot bolts into clutch housing mount on engine at 3 and 9 o clock position to guide assembly d Once the teeth have engaged the clutch shaft should engage full into the pilot bearing and the clutch housing bottom out against the engine There should be no gap between the housing and engine e Install the bolts which attach the clutch housing...

Page 41: ... than with a socket b OPTIONAL Install 1 crowfoot wrench onto dial type torque wrench and measure c Check clutch engagement torque of 100 10 lb ft N m d To adjust clutch engagement torque 1 Pull lock pin 1 2 Rotate adjusting yoke 2 in small increments CW to increase force CCW to decrease force 0760 054 4 4 1 2 3 Repeat steps a b and c until specification is achieved 4 Engage lock pin 5 Install ins...

Page 42: ...4 Verify correct machine operation Check for leakage a Start engine and engage clutch two to three times to allow centrifugal centering b Check all disturbed hydraulic hoses for leaks c Assure idle RPM is 1000 to 1100 RPM IMPORTANT Clutch engagement torque must be adjusted after ten hours of operation due to wear in of new components ...

Page 43: ...t Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Battery disconnected None FT1 Page Appdx B 1 Hydraulic tank drained Pumps will drain back into the tank during the tank draining procedure Pump drive shaft disconnected Machine blocked to prevent movement Catch container 1 gallon 3 8 L capacity NOTE Refer to Appendix C 1 of section A for additional re assembly information ...

Page 44: ... of machine Support brackets remain in machine Step 4 Drain oil from transmission box a Lower transmission drive box assembly to work surface Keep hoist or crane attached with enough tension to provide stability on the work surface b Place 1 gallon container beneath plug Remove bottom plug and then remove top plug 2 c After transmission box is drained install plugs 2 0721 07A DISASSEMBLY Step 1 Se...

Page 45: ...tch mark and remove gears b Remove bearings and seal c Clean and inspect all gear teeth splines and bearings d Replace any damaged components Discard seal 0721 15 Step 3 Clean mating surfaces on each half of transmission box BK 6 Step 4 Remove fabricated tooling ASSEMBLY NOTE Refer to Appendix C 1 of section A for addi tional details and hints Step 1 Install bearings and gears in outboard half of ...

Page 46: ...lube Step 2 Fill hydraulic tank Step 3 Fill all hoses and pump cases with hydraulic oil before starting engine Step 4 Connect battery Step 5 Start engine Step 6 Operate all hydraulic circuits several times to bleed air Step 7 Check for leaks d Place bearings 5 on gears with snap rings on inboard side 6 BK 21 5 6 Step 2 Apply surface sealant to the halves of the transmission box BK 6 1 Step 3 Assem...

Page 47: ...emoval Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Center deck plates raised None None Battery disconnected Machine blocked to prevent movement Transmission fluid catch container 10 5 pts 5 liters ...

Page 48: ...A b Sling housing and attach to hoist Take up slack c Remove mounting bolts 1 at rear of traction transmission under traction transmission motor d Remove mounting bolts 2 on each side of traction transmission e Remove traction transmission assembly 1 2 1144 78 DISASSEMBLY Step 1 Drain traction transmission fluid Transmission contains 10 5 pts 5 liters of fluid a Loosen transmission drain plug 4 b ...

Page 49: ...for wear looseness or damage Step 2 Inspect drive motor for leakage or damage Replace shaft seal if there is leakage Step 3 Inspect shift cap assembly for leakage or damage a Remove capscrews if there is leakage b Replace quad seals in the piston assembly Step 4 Inspect three speed transmission for leakage or damage ASSEMBLY Step 1 If further disassembly was required refer to Appendix A 1 for a li...

Page 50: ...ion drive motor mounting bolts securing motor to three speed transmission INSTALLATION Install the traction transmission assembly by reversing removal procedures EQUIPMENT PREPARATION Step 1 Fill traction transmission with transmission lube See Lubrication listing Step 2 Check hydraulic fluid level Step 3 Fill traction motor with hydraulic fluid Step 4 Connect battery Step 5 Start engine Run machi...

Page 51: ...s Removal Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Side panels removed None None Battery disconnected Machine blocked to prevent movement Transmission fluid catch container 10 5 pts 5 liters ...

Page 52: ... 5 6 6 5 4 7 0721 97A Step 3 Disconnect hydraulic hoses a Disconnect two hydraulic hoses 6 on shift cap assembly b Mark cap and plug all fittings and hoses Step 4 Tag and disconnect electrical connections 7 to the shift cap assembly Step 5 Disconnect traction drive motor a Sling housing and attach to hoist Take up slack b Remove traction drive motor 9 mounting bolts securing motor to three speed t...

Page 53: ...universal joints for wear looseness or damage Step 2 Inspect drive motor for leakage or damage Replace shaft seal if there is leakage Step 3 Inspect shift cap assembly for leakage or damage a Remove capscrews if there is leakage b Replace quad seals in the piston assembly Step 4 Inspect three speed transmission for leakage or damage ASSEMBLY Step 1 If further disassembly was required refer to vend...

Page 54: ... to the drop box 0721 114A Step 2 Install traction drive shaft a Install drive shaft 1 Torque bolts securing drive shaft to three speed transmission to 60 lb ft 82 N m b Install brake caliper mounting bracket 2 2 1 0721 97B Step 3 Install parking brake assembly a Install parking brake caliper 3 on disc 4 b Loosen adjusting screw 5 on caliper c Position caliper on brake disc d Tighten adjusting scr...

Page 55: ... with gear lube Step 2 Check hydraulic fluid Add if necessary Step 3 Connect battery Step 4 Start engine Run machine through shift ranges Step 5 Check for proper parking brake operation and adjust if necessary a With engine running and brake in the OFF position adjust parking brake adjustment screw b Place 0 0 012 0 31 mm feeler gauge between caliper and disc c Turn adjustment screw until there is...

Page 56: ...disconnected None None Two center deck plates lifted on all machines except PF 510 Machine blocked to prevent movement TRACTION DRIVE SHAFT ASSEMBLY This procedure covers Removal Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation ...

Page 57: ...case assembly 4 PF 510 only 2 3 1 0760 77B WHEELED MACHINE 1 3 4 0721 88A TRACKED MACHINE Step 2 Remove drive shaft a Slide shaft out b Pull assembly out of machine INSPECTION Step 1 Inspect drive shaft for wear looseness Step 2 Inspect U bolts for damage INSTALLATION Step 1 Install drive shaft a Apply thread sealant and install bolts securing shaft to disk flange Tighten to 60 lb ft 82 N m b Appl...

Page 58: ...covers Removal Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Drive chains disconnected None None Battery disconnected Machine blocked to prevent movement Catch container for brake fluid 3 qts 3 L ...

Page 59: ... with drive axle 0721 62B g Raise center deck plates above hydraulic and fuel tanks Step 2 Disconnect service brakes CAUTION Brake fluid is corrosive Be sure that brake fluid is drained into a proper container and not allowed to run down the side of the machine a Disconnect brake line 1 from master cylinder at calipers 2 on both sides of axle b Allow brake fluid to drain into catch container c Cap...

Page 60: ...lifting Step 6 Disconnect wire from the electric axle shift unit 6 6 0760 78A Step 7 Remove mounting bolts that secure drive axle to the brackets 7 7 0707 43A Step 8 Remove drive axle assembly CAUTION Use caution on both sides Make sure brake lines do not get pinched by the deck plates 0707 40 INSTALLATION Install the drive axle and brake assembly by reversing removal procedures ...

Page 61: ...n brake oil in a clean transparent container e Unscrew the bleed nipple about three quarters of a turn f Operate the left hand brake pedal with slow full strokes until the oil entering the container is free from air bubbles Maintain the level of oil in the relevant reservoir during this operation g When the oil entering the container is perfectly clear and free of air tighten the bleed nipple duri...

Page 62: ...FT UNIT This procedure covers Removal Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Battery disconnected None None Center deck plates lifted ...

Page 63: ...secure shifter to axle b Remove shifter unit from the drive axle BK 172 4 4 3 4 4 2 4 4 1 INSTALLATION Step 1 Install shifter unit 2 a Place shifter on shafts b Install nuts and washers to secure unit to axle Step 2 Install electrical plug to shifter unit 1 EQUIPMENT PREPARATION Step 1 Connect battery Step 2 Test paver a Run paver shift from LO to HI to check that shifter unit works properly ...

Page 64: ...ers Removal Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Splash guard in front of left tire None None removed if changing left tire Battery disconnected Machine blocked to prevent movement ...

Page 65: ...760 81A Step 2 Disconnect drive chain a Remove chain guard mounting bolts b Remove chain guard 2 0760 58A 2 c Find master link link with the cotter pins You may have to rotate tire to find master link d Remove cotter pins 3 from master link e Remove link pins This will break the chain 3 1144 82A Step 3 Remove wheel a Remove lug nuts that hold wheel on hub 0760 79 b Pull wheel off of hub Drive chai...

Page 66: ...ysical injury or death These are instructions for the hydroflation of the drive tires on the highway class paver finisher Follow these instructions to displace most of the air The hydroflation allows the tire to be inflated to a low pressure to provide the proper footprint and maximum tractive effort Hydroflation also reduces wheel bounce which affects paving quality Follow these instructions enti...

Page 67: ...rque 0760 79 Step 2 Install drive chain a Place chain over tire sprocket and the axle sprocket Note Install with cotter pins away from tire b Install link pins c Install cotter pins to master link This will secure chain d Adjust chain tension See Drive Chain and Tightener Assembly e Install chain guard BK 23 Step 3 Lower tractor a Jack or lift machine off hardwood blocking b Remove blocks from und...

Page 68: ...rocedure covers Removal Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Machine blocked to prevent movement None None Machine raised Drive chain removed Wheel assembly removed Battery disconnected ...

Page 69: ... spindle 7 a Secure lifting device to spindle shaft Sling housing and take up slack b Remove four bolts 8 that secure spindle to machine frame c Lower spindle to floor DISASSEMBLY Step 1 Disassemble hub assembly a Remove bearing cones b Pull bearing cups 0760 89 INSPECTION Step 1 Inspect bearings for wear and damage Step 2 Inspect wheel studs and lug nuts for damage Step 3 Inspect spindle weldment...

Page 70: ... 40 80 lb in 54 108 N m e Install lock washer 2 and bend one tab on inner nut notch f Install outer lock nut 1 and hand tighten bend one tab of lock washer 2 on outer nut notch If necessary back nut off slightly to align tab with notch 3 1 2 4 BK 164 Step 5 Install tire a Place tire on hub b Install lug nuts to secure tire Torque lug nuts to 320 lb ft 434 N m dry torque 240 lb ft 325 N m wet torqu...

Page 71: ...Paver Finishers A 71 EQUIPMENT PREPARATION Step 1 Connect battery Step 2 Lower machine to the ground Step 3 Test machine a Start engine b Move machine forward c Check that tires do not wobble or are loose d Recheck chain tension ...

Page 72: ...pecification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools On left side of machine extra splash guard None None will have to be removed before chain guard can be removed Machine blocked to prevent movement Battery disconnected ...

Page 73: ...on tensioner 4 b Remove two bolts 5 on wheel spindle 6 3 4 6 5 1144 64 INSPECTION Step 1 Inspect chain a Inspect chain for wear or damage b Inspect chain for proper tension If not adjust able remove either the offset 1 2 link or a full link from the drive chains as required Then adjust IMPORTANT Mark sprocket cover and or machine records when one full link has been removed If one full link has bee...

Page 74: ...overs over each axle sprocket Step 2 Loosen the wheel spindle bolts just enough to allow the spindle and hub assemblies to slide on the paver frame Step 3 Tension chain a Rotate the wheel to locate the flat washer inside of each rim at the point where it is furthest from drive sprocket Flat washer 8 indicates sprocket high point 8 0738 15A b Loosen the jam nut 9 and adjust the tensioner until ther...

Page 75: ...stallation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Auger lowered Internal Keyed None Screed lowered Spanner Wrench Battery disconnected Snap On MAC Catch container for transmission fluid 16 qts 15 L Whittet Higgins Co Wash down assembly removed if necessary ...

Page 76: ...lug at the bottom of the traction case b Allow lubricant to drain into the catch container c Install drain plug when fluid has finished drain ing Step 4 Remove traction case a Attach lifting device around traction case assembly b Remove traction case dipstick pipe c Remove mounting bolts NOTE Watch out for shims d Lift traction case away from the machine e Remove tag and mark traction case shims f...

Page 77: ...Drive Train Highway Class Paver Finishers A 77 BK 47 2 1 ...

Page 78: ...ring gear subassembly 9 BK 25 1 9 4 6 8 2 5 3 7 Step 4 Remove intermediate gear a Remove cap screws 1 and retainer plate 2 b Remove bearing cup 3 c Remove idler pin 4 d Remove gear assembly 5 e Remove bearing cone 6 and spacer 7 f Remove bearing cone 8 cup 9 and retaining ring 10 g Remove O rings 11 and 12 from idler pin 4 BK 145A 4 11 12 8 9 10 5 7 3 6 2 1 Step 5 Remove drive sprocket Use special...

Page 79: ...p yoke 4 from moving and remove nut and washer 5 c Remove pinion shaft 6 and bearing cone 7 d Pull seal 8 from housing e Remove bearing cone 9 and cup 10 f Remove spacer 11 and shims 12 Tag shims g If necessary pull bearing cup 13 from housing BK 27 1 2 3 4 8 9 10 7 6 5 12 11 13 Step 8 Disassemble ring gear subassembly a Remove shims 1 and O ring 2 from bearing cap 3 b If necessary pull bearing cu...

Page 80: ...ars for wear and damage Step 3 Check all shafts for wear and damage PINION AND RING GEAR ASSEMBLY IMPORTANT If bearings and cones are bad they must be replaced in sets CAUTION Do not install pinion seal 8 until pre load is adjusted BK 27 1 2 3 4 8 9 10 7 6 5 12 11 13 Step 1 Assemble pinion subassembly to determine preload a If removed press bearing cups 10 and 12 into pinion housing 3 b Assemble b...

Page 81: ...t end play 2 1 BK 140 3 FIXTURE DIAL INDICATOR c With pinion shaft horizontal pull on shaft set the dial indicator to zero and then push on shaft to measure end play d Determine proper preload using the worksheet Measured Endplay _____ Preload 0 003 Shim Thickness to Remove _____ e Disassemble pinion and remove shims as determined above in step d Step 3 Assemble pinion subassembly a Install seal 1...

Page 82: ...ter cup 6 f Apply grease to bearings g Install seal 7 h Install retaining cap 8 with O ring 9 i Install bolts 10 with thread sealant Tighten in criss cross pattern and torque to 60 65 lb ft 85 N m 0707 30 j Install seal shield 11 k Install bearing cone 12 on opposite end of shaft l If removed press bearing cup 13 in bearing cap 14 Step 3 Adjust output shaft pre load a Use a feeler gauge to check t...

Page 83: ...position in cups g Install O rings 8 and 9 on idler pin 10 h Position gear assembly in case and install idler pin i Align pin retainer holes 2 with those in case 0707 15 j Install retainer plate 11 with cap screws 12 using thread sealant k Tighten cap screws and torque to 35 lb ft 48 N m Step 5 Assemble ring gear subassembly a Secure cross shaft 2 in vise with jaw protec tors b Position ring gear ...

Page 84: ... outside and 0 040 1 01 mm shim pack on inside Do not install O rings 11 and 12 until final case assembly e Install 4 cap screws 13 and 14 in each bearing cap 90 apart Do not use thread sealant on cap screws until final case assembly f Install dial indicator 0707 21 g Push shaft fully in one direction set the dial indicator to zero and then pull shaft in opposite direction Note reading h Add 0 007...

Page 85: ...nd lock washers Tighten in criss cross pattern and torque to 60 65 lb ft 85 N m d Install dial indicator 0707 25 e Check for backlash between 0 004 and 0 008 0 10 and 0 20 mm It is necessary to lock the pinion from rotating to get an accurate backlash reading f If necessary move shims from one ring gear bearing cap to another to get proper backlash DO NOT change shim pack size once pre load has be...

Page 86: ...rive pinion BK 33 PATTERN B BK 34 PATTERN C f If tooth pattern is profile bearing high or profile bearing low pinion pre load is incorrect Re move and reassemble pinion subassembly BK 35 PATTERN D BK 36 PATTERN E NOTE There are two types of sprockets available for the traction case One is a three segment sprocket The other is a one piece sprocket Follow the procedure that applies to your machine S...

Page 87: ...caps and use thread sealant on cap screws Step 13 Install drain plug Step 14 Install case access cover a Apply surface sealant b Install bolts with lock washers and tighten in criss cross pattern Torque to 60 65 lb ft 81 88 N m Step 15 Fill case with lubricant a Fill to halfway up outside bearing cap horizontal screw holes b Recheck level with dipstick after installing on machine ADJUSTMENT Check ...

Page 88: ... the traction case as necessary to eliminate any gaps to within 1 32 0 79 mm e Install and tighten top mounting bolts Torque to 325 lb ft 440 N m f Install traction case fill pipe 0718 23 Step 2 Apply thread sealant to U bolts and connect traction drive shaft to traction case Torque U bolts to 60 lb ft 81 N m 0718 13 Step 3 Install side deck plates and support bracket Step 4 Connect track see Trac...

Page 89: ...ication Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Paver on flat surface None None Screed and side arms removed Hopper wings raised Catch pan for track tensioner hose 3 qts 2 8 L Cap and plug for track tensioner hose 2 people required ...

Page 90: ... the hydraulic tube mounting bracket 2 c Cap and plug all fittings and hoses to prevent fluid loss and contamination 1 2 0718 10B Step 3 Locate band joint one can be found every 32 81 cm or 8 pads in a section of track at bottom of track just in front of drive sprocket if removing from the rear or just behind front take up wheel if removing from the front Step 4 Disconnect band joint a Remove pad ...

Page 91: ...Step 3 Disconnect band joint a Remove pad nuts 1 from inside and outside b Remove guides 2 from inside and outside c Pry inside and outside track bands 3 from the track shoe 4 1 2 3 4 0718 11A Step 4 Drive off track a Move machine forward using the opposite track for power b Move until the forward end of track lays on the ground at the front take up wheel 1 1 0718 20A INSPECTION IMPORTANT Refer to...

Page 92: ...ll nuts onto pad studs and start threads g Tighten the nuts against the guides using the tightening sequence illustrated for setting nuts BK 37 1 2 3 4 INSIDE OF TRACK 1 2 3 4 CAUTION Locknuts should not be tightened in excess of 35 lb ft 47 N m at this time It is important that the track band be compressed evenly and that the guides and shoes contact each other NOTE A calibrated torque wrench sho...

Page 93: ...eding the track up over the sprocket b Continue forward slowly feeding the track over the bogie wheels 0718 60 Step 3 Pull slack out of track and join the ends beneath the front take up wheel BK 52 Step 4 Install track a Move the joint to the rear on the ground again in front of the drive sprocket b Place band over shoe bolts c Install guide plates d Install nuts onto pad studs and start threads C...

Page 94: ...ck tension cylinder a Remove cap and plug b Connect hose 1 at the hydraulic tube mounting bracket 1 0718 10A TRACK TENSION ADJUSTMENT Step 1 Adjust take up wheel position a Start engine b Loosen track tension cylinder bleeder screw 1 c Engage manual clutch to bleed cylinder of air until a solid stream of hydraulic fluid without air bubbles is seen d Tighten bleeder screw track tension will adjust ...

Page 95: ... Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Machine blocked to prevent movement None None Hopper wings raised Controls locked out to prevent accidental start up ...

Page 96: ...e machine Inside track bands are most easily replaced by removing the track from the ma chine Step 1 Release track tension a Loosen track tension bleeder screw 1 until all tension is released b Tighten bleeder screw 1 0718 40A Step 2 Remove track guides to give access to the track bands a Remove track guide nuts 1 b Lift guides 2 off of tracks 1 2 0718 09 WARNING Do not cut or burn track pads or t...

Page 97: ...rated in final torque sequence BK 38 1 4 2 3 INSIDE OF TRACK 1 4 2 3 INSTALLATION Step 1 Install track band Place band 1 over track pad studs 2 0718 62A 1 2 Step 2 If track was removed install track See DRIVE TRACK ASSEMBLY for track installation procedures Step 3 Install track guides a Install guide plates 1 b Install nuts 2 onto pad studs and start threads 2 1 0718 09B CAUTION Locknuts should no...

Page 98: ...er screw 1 c Engage manual clutch to bleed cylinder of air until a solid stream of hydraulic fluid without air bubbles is seen d Tighten bleeder screw track tension will adjust BK 39 1 Step 2 Check track operation a Drive machine in reverse for one full track revolution b Drive machine forward for two full track revolu tions c Verify proper track tension by sight EQUIPMENT PREPARATION Step 1 Check...

Page 99: ...rs Removal Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Machine blocked to prevent movement None None Controls locked out to prevent accidental start up ...

Page 100: ...nuts are accessible through the space between the front of the drive sprocket and the last bogie wheel IMPORTANT If a pad located at a band joint is to be replaced be sure to first bleed the track tension cylinder before removing the pad Step 1 Position the track pad where it is most accessible for removal Step 2 Loosen the track tension cylinder bleeder screw 1 before removing an old track pad if...

Page 101: ... 1 0718 09B CAUTION Locknuts should not be tightened in excess of 35 lb ft 47 N m at this time It is important that the track band be compressed evenly and that the guides and shoes contact each other c Tighten the nuts against the guides using the tightening sequence illustrated for setting nuts Tighten to 35 lb ft 47 N m at this time BK 37 1 2 3 4 INSIDE OF TRACK 1 2 3 4 d Torque nuts on each gu...

Page 102: ...te all fittings with proper grease IMPORTANT Repeating the torque sequence is absolutely necessary to achieve final torque specification e Repeat the torque sequence on each guide twice before proceeding to the next guide Step 4 Tighten track tension cylinder bleeder screw 1 if loosened 1 0718 40A TRACK TENSION ADJUSTMENT Step 1 Adjust take up wheel position a Start engine b Loosen track tension c...

Page 103: ...emoval Inspection Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Machine blocked to prevent movement None None Screed secured in the raised position Hopper wings raised Battery disconnected ...

Page 104: ...ack band off of studs c Pull track off of the top of the bogie wheels using the drive sprocket and a towing vehicle to pull the track under the bogies Leave the track under the bogie wheels and on top of the drive sprocket for easier installation 0718 31 NOTE Machine might have to be jacked higher for bogie wheel assembly to clear track guides Step 4 Remove bogie wheel assembly NOTE Middle bogie a...

Page 105: ...18 34A DISASSEMBLY Step 1 Remove bogie wheel a Remove hub cap b Remove locknut 1 c Remove lockwasher 2 d Remove retaining washer 3 1 3 2 0718 35A e Pull tire off of spindle f Remove bearing cups and cones 0718 37 Step 2 Press tire from rim WARNING Do not cut or burn urethane bogie assembly Noxious fumes are harmful if inhaled NOTE When pressing tires off rims access to a 100 ton press is needed ...

Page 106: ...HEEL OR MACHINE Step 2 Install bogie wheel a Install bearing cups and cones and shims if necessary b Slide bogie wheel onto spindle c Install retaining washer 3 d Install lockwasher 2 e Install locknut 1 and torque f Check torque using string line and fish scale on outer surface of tire Pull scale in straight line with even force A reading of 5 10 lbs 2 2 4 5 kg produces correct torque g Install h...

Page 107: ...ct grease fitting 3 from top of assembly b Install locknuts 2 and lockwasher Place lockwasher between locknuts c Bend one lock tab 1 over notch in each locknut 1 3 2 0718 16A IMPORTANT Make sure bogie wheels fit between track guides Step 4 Lower machine to the ground Step 5 Connect drive track see Drive Track Assembly EQUIPMENT PREPARATION Step 1 Connect battery Step 2 Adjust track tension See Dri...

Page 108: ...n Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Machine blocked to prevent movement None None Screed secured in the raised position Hopper wings raised blocked or chained in position Battery disconnected ...

Page 109: ...T BOGIE 4 1 2 2 1 1 3 2 1 1 Step 3 WARNING Block or strap hopper wings in the raised position before removing hopper cylinder pin Remove pins from hopper lift cylinder 4 and remove if necessary for access PF 171 and PF 172 only Step 4 Disconnect long tie rod from front wheel a Remove stud nut 1 and lift tie rod 2 off of stud b Pull long tie rod through machine Only if removing bogie wheels on both...

Page 110: ...ylinder b Remove cotter pin 3 on rod clevis of cylinder c Pull clevis pin from cylinder 4 d Remove cylinder 3 4 1 2 4 1144 92 Step 8 Remove king pin arms a Remove cotter pin 1 nut 2 and bolt 3 b Remove king pin arm 4 c Remove bearing cups 5 d Pull bearing cones 6 if necessary e Press out bearing sleeve if necessary BK 44 STANDARD FRONT WHEEL BOGIE PF 200 STANDARD FRONT WHEEL BOGIE PF 171 AND PF 17...

Page 111: ...ress out cones if necessary 1 2 3 4 5 0721 25 Step 2 Press tire from rim NOTE When pressing tire from rim access to 100 ton press is needed DISASSEMBLY FRONT WHEEL POWER ASSIST Step 1 Remove wheel tire assembly for front wheel assist a Remove manifold 1 at the back of the motor b Remove spanner nuts 2 c Remove motor and wheel assembly d Remove motor 3 from wheel 4 BK 45A 1 2 3 4 Step 2 Press tire ...

Page 112: ...h with edge of rim NOTE When pressing tire on rim access to 100 ton press is needed Step 2 Install bogie wheel a Press bearing cones into rim b Pack bearings with grease c Install bearing cups and cones d Slide bogie wheel onto hub 1 e Install retaining washer 2 lockwasher 3 and locknut 4 f Install hub cap 5 PF 171 only BK 44A STANDARD FRONT WHEEL BOGIE PF 200 STANDARD FRONT WHEEL BOGIE PF 171 AND...

Page 113: ... Specification Installation Disassembly Assembly Adjustments Special Cleaning Component Test Equipment Preparation Machine Set up Special Tools Fabricated Tools Machine blocked to prevent movement None None Jack up front of machine for clearance Screed secured in the raised position Hopper wings raised Battery disconnected ...

Page 114: ... adequate work space b Remove lug nuts remove cover c Remove nut and lockwasher d Pull tire off shaft 0718 47 DISASSEMBLY Step 1 Remove track tension cylinder a Remove hydraulic line 1 to track tension cylinder 2 b Lift track up to give adequate work space c Loosen set screw 3 at rear of tension cylinder d Pull cylinder pin 4 out e Push take up wheel shaft forward cylinder drops down 4 2 1 3 0718 ...

Page 115: ...ld cylinder pin in place e Connect hose 1 to track tension cylinder f Tighten bleeder screw 5 5 4 2 1 3 0718 40B INSTALLATION Step 1 Install take up wheel a Lift track up to give adequate work space b Place tire on shaft c Install nut and lockwasher Rotate wheel backward as you tighten to seat bearings d Install cover install lug nuts 0718 50 ADJUSTMENT Step 1 Adjust take up wheel position a Loose...

Page 116: ...y 00164 646 00 Farr P N 60477 2 Product Data Sheets and Air Cleaner Manual Book WD Radiator 00164 755 00 Modine P N 1A14596D Oil Cooler 00164 787 00 Modine P N 1E2979C 00164 208 00 Dunham Bush P N RB3 002G or Hayden P N 002198 Water Temperature 00155 037 00 VDO Instrument P N 1 531 006 169 Sending Unit Oil Pressure Sending Unit 00155 027 00 Datcon Instrument P N 155 23 1 8NPT Hour Meter Switch 001...

Page 117: ...Highway Class Paver Finishers Drive Train ...

Page 118: ... Fabricated Tools Appdx B 1 7 8 7 8 1 2 1 4 10 3 4 12 1 2 11 5 8 5 5 16 6 3 8 KEYSTOCK 2 HOLES FOR BOLTS TO SECURE BRACKET TO PUMP 2 HOLES FOR BOLTS TO SECURE BRACKET TO PUMP NUTS WELDED TO BOTTOM OF 3 HOLES BK 165 FT1 PUMP BOX BRACKETS TOP BRACKET BOTTOM BRACKET ...

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