Fayat Bomag CR 820 T Tier 4 Operating Instructions, Maintenance Instructions Download Page 21

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2 Safety

Date May 2020

Page 2-5

Operations Manual
CR 820 T

Crush Hazard
Crush from runaway machine.

Crush Avoidance
Place machine on level ground

and block wheels.

Explosion Hazard
Battery explosion.

Explosion Avoidance

Keep open flames away.

Explosion Avoidance
Do not smoke.

Burn Hazard
Burns from corrosive chemical.

Avoidance
Read and understand operator’s

manual before using equipment.

Injection Hazard
Skin injection from high pres-

sure fluid.

Injection Avoidance
Use cardboard or wood to

search for leaks.

ANSI Decals

Decal #1

- Crush Hazard Hopper Wings

0449150006

Decal #2

- Crush Machine Movement

001010662000

Summary of Contents for Bomag CR 820 T Tier 4

Page 1: ...00808924 05 20 Operating Instructions Maintenance Instructions CR 820 T Tier 4 Hot Mix Asphalt Paver ...

Page 2: ...Intentionally Left Blank ...

Page 3: ...Table of Contents Date May 2020 Page 1 Operations Manual CR 820 T TABLE OF CONTENTS ...

Page 4: ...el Leaks 1 4 Check the condition of the fuel hoses 1 4 Check the Turbocharger 1 4 Product Identification Plate 1 4 Intended Use 1 4 Prohibited Use 1 4 Bulletin Compliance 1 5 Contacting Authorized Bomag Dealer Distributor 1 5 Register Machine 1 5 Transfer of Machine Ownership 1 5 2 SAFETY 2 1 Owners Users and Operators 2 2 General Safety 2 2 Safety Alert Symbol 2 2 ANSI Hazard Classification Syste...

Page 5: ... Console 4 5 Display Icon Buttons 4 6 Additional Display Icon Buttons 4 7 Warning Lamp Icons 4 9 Operator s Display 4 10 Display Screens 4 10 Splash Screen 4 10 Main Run 1 Screen 4 13 Left Gauge Cluster 4 13 Right Gauge Cluster 4 13 Center Gauge Cluster 4 13 Lower Screen Area 4 13 Left Side Button Icons 4 14 Right Side Button Icons 4 14 Lower Cursor Buttons 4 14 Warning Lamps 4 15 Main Run 2 Scree...

Page 6: ... 2 Ground Clearance 5 2 Driving the Paver On Off the Trailer 5 3 Preparation for Transport 5 4 6 INITIAL SETUP AND ADJUSTMENTS 6 1 Unload and Install the Screed 6 2 7 STANDARD OPERATING PROCEDURES 7 1 Pre Operating Checks 7 2 Raising the Center Hood 7 2 Lowering the Center Hood 7 3 Inspection 7 4 Start Up 7 5 Starting the Engine 7 5 Preparing to Pave 7 6 Raise Lower Screed 7 6 Fume Recovery System...

Page 7: ...ries 8 2 Emergency Stop 8 3 Lockout and Tagout Procedure 8 3 Emergency Towing 8 4 9 MAINTENANCE 9 1 Service Parts 9 2 Maintenance Schedule 9 2 When Needed 9 2 Every 8 Service Hours or Daily 9 2 After First 40 Service Hours Only 9 3 Every 40 Service Hours 9 3 After First 150 Service Hours 9 3 Every 250 Service Hours 9 3 After First 500 Service Hours 9 4 Every 500 Service Hours 9 4 Every 1000 Servic...

Page 8: ... 15 Replace Fuel Filter Water Separator 9 15 Hydraulic System 9 16 Check Hydraulic Tank Oil Level 9 16 Clean Strainer and Replace Hydraulic Fluid 9 16 Check Hydraulic Lines and Components 9 17 Replace Charge Filters 9 18 Replace Auxiliary Pump Filter 9 18 Adjust Pump Drive Belt Tension 9 19 Electrical System 9 21 Inspect Battery Cables 9 21 Storing Batteries 9 22 Ground Drive System 9 22 Check Fin...

Page 9: ...Table of Contents Date May 2020 Page 7 Operations Manual CR 820 T Storing the Machine 10 2 Machine Storage Preparation 10 2 Release Track Tension 10 2 ...

Page 10: ...Table of Contents Operations Manual CR 820 T Date May 2020 Page 8 Intentionally Left Blank ...

Page 11: ...1 INTRODUCTION Date May 2020 Page 1 1 Operations Manual CR 820 T 1 INTRODUCTION ...

Page 12: ...ety alert symbol indicates a risk of personal injury Fol low all instructions which appear after this safety alert symbol in order to avoid injury or potentially fatal accidents Safety Notes In the operations manuals all safety notes will cov er ANSI versions These safety instructions must be fully read and understood before carrying out any work with or on the machine Failure to do so could resul...

Page 13: ...y is properly administered Contact the nearest Bomag regional office in the event that warranty service covered under the Emission Control System Warranty received is un satisfactory Normal Non Road Engine Use The maintenance instructions are based on the assumption that this conventional machine will be used as designated in the operator s instruction manual and operated only with the specified f...

Page 14: ...49 ºC 660 ºF and cetane minimum 45 In order to avoid excessive sedimentation and to minimise the missions of sulfur dioxide the fuel s sulfur content should be as low as possible The diesel fuels recommended for use shall meet ASTM designation D 975 no 1D C B or no 2D T T with a cetane level above 42 and sulfur content not exceeding 0 05 percent by weight Check for Fuel Leaks with the engine runni...

Page 15: ...accurate Contacting Authorized Bomag Dealer Distributor These are specific times when you should contact the company These include Accident Reporting Current owner updates Questions regarding product appli cations and safety Standards and regulations compli ance information Questions regarding product modifi cations Register Machine Your dealer will register your machine and its war ranty with the...

Page 16: ...1 INTRODUCTION Operations Manual CR 820 T Date May 2020 Page 1 6 Intentionally Left Blank ...

Page 17: ...2 Safety Date May 2020 Page 2 1 Operations Manual CR 820 T 2 SAFETY ...

Page 18: ...s All per sonnel should have the necessary training skills and tools to perform these functions properly Safety Alert Symbol In conjunction with the text which follows it this safety alert symbol is used as a safety warning system in these operating instructions The safety alert symbol indicates a risk of personal injury Fol low all instructions which appear after this safety alert symbol in order...

Page 19: ...oving components Never wear loose clothes long hair coat tails jewelry pockets full of tools or any other item that could get caught in moving parts Safety Shoes To protect against heavy falling parts and slipping on slippery ground Protective Gloves To protect the hands against excoriation punctures or deep injuries against irritating and caustic substances as well as against burns Leather gloves...

Page 20: ...ily inspection of the equipment check that the decals are present and in good condition Safety Sign Pictorials Symbol Description Crush Hazard Crush from paver hopper wings Crush Avoidance Stay clear of hopper wings Crush Hazard Crush from machine movement Crush Avoidance Stay away from machine Entanglement Hazard Leg entanglement in auger Entanglement Avoidance Stay clear of auger Burn Hazard Bur...

Page 21: ...sion Avoidance Keep open flames away Explosion Avoidance Do not smoke Burn Hazard Burns from corrosive chemical Avoidance Read and understand operator s manual before using equipment Injection Hazard Skin injection from high pres sure fluid Injection Avoidance Use cardboard or wood to search for leaks ANSI Decals Decal 1 Crush Hazard Hopper Wings 0449150006 Decal 2 Crush Machine Movement 001010662...

Page 22: ...nual CR 820 T Date May 2020 Page 2 6 Decal 3 Safety Crush Auger 0449040004 Decal 4 Safety Burn Hot Asphalt 0449150003 Decal 5 Safety Crush Hood 0449150004 Decal 6 Safety Fall 0449150007 Decal 7 Safety Entanglement 0449150016 ...

Page 23: ...2 Safety Date May 2020 Page 2 7 Operations Manual CR 820 T Decal 8 Safety Hearing Hazard 0449150005 Decal 9 Safety Runaway Machine 0449150011 Decal 10 Safety Injection 0449150010 ...

Page 24: ...2 Safety Operations Manual CR 820 T Date May 2020 Page 2 8 Decal 11 Safety Explosion Hazard 0449040014 Decal 12 Safety Accumlator Dry Nitrogen 0449040012 ...

Page 25: ...2 Safety Date May 2020 Page 2 9 Operations Manual CR 820 T Additional Decals Decal 13 Emergency Towing 0449410301 Decal 14 Paver Patents 05020030 ...

Page 26: ...2 Safety Operations Manual CR 820 T Date May 2020 Page 2 10 Decal 15 Hot Mix and Lubrication 91312954 Decal 16 Tie Down Points 05020034 ...

Page 27: ...2 Safety Date May 2020 Page 2 11 Operations Manual CR 820 T Decal 17 Paver Lifting Points 91313699 Decal 18 Paver Serial Plate 91311979 ...

Page 28: ...2 Safety Operations Manual CR 820 T Date May 2020 Page 2 12 Decal 21 Lift Point 0449350001 Decal 22 Tie Down Point 0449350003 Decal 19 California Prop 65 00833968 Decal 20 Do Not Step 0449350005 ...

Page 29: ...2 Safety Date May 2020 Page 2 13 Operations Manual CR 820 T Decal 23 Paver Moving Instructions 91312955 ...

Page 30: ...2 Safety Operations Manual CR 820 T Date May 2020 Page 2 14 Decal 24 Emblem SMV 04418197 Decal 25 Vacuum Indicator 04418934 ...

Page 31: ...2 Safety Date May 2020 Page 2 15 Operations Manual CR 820 T Decal 26 Crush Warning 05020951 Decal 27 Emulsion Fill 00833599 ...

Page 32: ...2 Safety Operations Manual CR 820 T Date May 2020 Page 2 16 Safety Sign Locations Figure 2 1 Left Side View Figure 2 2 Rear View ...

Page 33: ...2 Safety Date May 2020 Page 2 17 Operations Manual CR 820 T Figure 2 3 Right Side View Figure 2 4 Front View ...

Page 34: ...agout procedure should be per formed in the following situations Any time anyone is maintaining repairing lubricating or for whatever reason working on the equipment When the equipment is broken or for what ever reason unfit or unsafe to operate While clearing blocked or jammed mecha nisms Whenever the equipment is left unattend ed Unexpected operation of plant components dur ing service or repair...

Page 35: ...ting Relieve all pressure in air systems before any lines fittings or related items are loosened disconnected or removed Never remove any guard cover or shield when this equipment is in operation Replace guards covers and shields when the task for which you removed them is finished Never attempt to clear away jammed feed material discharge material or other stoppage while the ma chine is running S...

Page 36: ...el to ensure that the changes include appropriate guard ing and provide a safe working environment for all personnel Allow only the operator on the operator s platform when the paver is in operation Before starting the paver make sure all personnel are clear Before leaving the operator s seat stop the paver by putting the FNR in the STOP position and set ting the parking brake Reduce travel speed ...

Page 37: ...te in on or around the ma chine Do not expose components to independent flames of any type Do not bend or strike high pressure lines Do not install bent or damaged lines tubes or hoses Repair any loose or damaged fuel lines Leaks can cause fires Make sure that all clamps guards and heat shields are installed correctly to prevent vibration rubbing against other parts and excessive heat during op er...

Page 38: ...2 Safety Operations Manual CR 820 T Date May 2020 Page 2 22 Intentionally Left Blank ...

Page 39: ...3 Technical Data Date May 2020 Page 3 1 Operations Manual CR 820 T 3 TECHNICAL DATA ...

Page 40: ...ow on Dipstick 3 Qt 2 84 L Emulsion 5 5 Gal 20 8L Hopper 10 tons 10 2 tonnes Recommended Fluids Diesel Fuel Ultra Low Sulfur Diesel with a maximum sulfur content of 15 ppm in the United States and 10 ppm in the European Union Engine Lubricating Oil Oil that meets Petroleum Institue Classification CJ 4 SL and Cummins engineering classification CES 20081 for a high quality heavy duty low ash engine ...

Page 41: ...4 Operator Controls Date May 2020 Page 4 1 Operations Manual CR 820 T 4 OPERATOR CONTROLS ...

Page 42: ...ages the trucks wheels Rotate the needle valve clockwise to reduce the engage speed and counterclockwise to engage the truck hook quicker 3 Flow Gates enables both right hand or left hand flow gates to move up and open The gates regulate the depth of mix carried to each auger The spring loaded switches must be held at RAISE or LOWER until the desired gate height is obtained When re leased the swit...

Page 43: ...Idle 900 RPM when the FNR is brought back to neutral 10 Travel Pave Speed Toggle The speed switch has 3 positions TRAVEL Use for roading or traveling around the job site P 2 use for paving in normal drive P 4 if the paver is not equipped with the optional Front Wheel Assist it op erates the same as for P 2 Use this position to change to front wheel assist Engaging the optional front wheel assist w...

Page 44: ...for screed R L procedure 18 Screed Vibration The vibrators switch will function only when the FNR is forward Push up to turn the vibrators on and push down to turn the vibrators off 19 Console Control Button Operator pres ence selection is the method used by the operator to enable either the right or left tractor control console by pressing a switch on the selected console Each console is equipped...

Page 45: ...4 Operator Controls Date May 2020 Page 4 5 Operations Manual CR 820 T Operator s Console 7 12 19 6 C A 15 3 2 18 F G B D E Figure 4 2 Display Icon Buttons ...

Page 46: ...nctions 3 Diagnostics 4 Descending Values 5 Engine Diagnostics 6 Beacon Flasher 7 Fuel Tank 8 Fuel Tank Left Not appli cable to the CR554 9 Fuel Tank Right Not appli cable to the CR554 10 Front Wheel Assist 11 Home 12 Low Hopper Alarm 13 Paver Diagnostics 14 Save 15 Setup Calibration 16 Steering 17 Incrementing Values 18 Uphill Mode 19 Working Lights ...

Page 47: ...ons Item Symbol Description A Console Status Green Active Red Inactive B Auto Throttle C Screed Assist D Screed Vibrators Animated Motion ON E Left Spreading Auger Converyor Animated Motion ON F Right Spreading Auger Conveyor Animated Motion ON G Travel Mode H Closed Loop Steering I Center Steering ...

Page 48: ...4 Operator Controls Operations Manual CR 820 T Date May 2020 Page 4 8 6 3 8 9 7 2 5 4 10 1 11 Figure 4 3 Warning Icons ...

Page 49: ...olant Temp 3 DEF Level 4 Engine Warning Red Stop Engine Yellow Warning 5 Engine Oil Pressure 6 ESC 7 HEST 8 Hydraulic Temp 9 Parking Brake Green AutoBrake ON Brake OFF Red Brake ON Flashing Red Green AutoBrake ON Brake ON 10 Wait to Start 11 Message Center If shown contact autho rized Bomag dealer dis tributor CAN ERROR Detrack Warning ...

Page 50: ...eens are Main Run 1 Main Run 2 Main Diagnostics Engine Faults Paver Diagnostics Message States 1 Message States 2 Message States 3 Advanced Functions Uphill Mode Set up The calibration screens are Main Set up Propel Calibration Steering Calibration Threshold Calibration Maximum Calibration Splash Screen When the engine ignition switch is turned to the ON position the micro controller is powered up...

Page 51: ...4 Operator Controls Date May 2020 Page 4 11 Operations Manual CR 820 T C A F G B D E 11 H 2A Figure 4 5 Main Run Screen with Message Center ...

Page 52: ...4 Operator Controls Operations Manual CR 820 T Date May 2020 Page 4 12 1 8 23 5 13 12 4 9 15 11 19 3 18 2 17 16 10 20 7 21 22 6 14 Figure 4 6 Main Run Screen ...

Page 53: ...eet per minute Paver ground speeds greater than 120 feet per minute are depicted in miles per hour The Ground Speed is also displayed in gauge format to a maximum of 80 feet per minute Propel 10 Figure 4 6 is displayed digi tally below the Ground Speed Speed Knob percentage 0 to 100 set ting 11 Figure 4 6 is displayed as a bar graph below the Propel Engine RPM 12 Figure 4 6 is displayed in gauge f...

Page 54: ...uel level of greater than 10 Ared icon indicates that the Fuel Tank Status has a fuel level of 10 or less Right Side Button Icons Calibration Menu machine set up 20 Figure 4 6 is displayed adjacent to the top button Button 5 Navigation to the Main Calibration page is accomplished by pressing Button 5 Diagnostics Menu 21 Figure 4 6 is dis played adjacent to the second from the top button Button 6 N...

Page 55: ...s on page 4 8 that are located across the top of the screen They behave the same way on each screen and are activated by the engine and system messages Main Run 2 Screen Pressing 5 RIGHT button while the Main Run 1 screen is displayed will navigate to the Main Run 2 display screen 31 2 2A 38 10 9 8 32 33 34 35 36 37 Figure 4 8 Main Run Screen 2 ...

Page 56: ...4 Operator Controls Operations Manual CR 820 T Date May 2020 Page 4 16 C B H D Figure 4 9 Main Run Screen ...

Page 57: ... The speed is displayed digitally in feet per minute up to 120 feet per minute The Ground Speed is also displayed in gauge format to a maximum of 80 feet per min ute Propel 10 Figure 4 8 is displayed digi tally below the Ground Speed Engine RPM 38 Figure 4 8 is displayed in gauge format below the Propel Auto Throttle ON OFF B Figure 4 9 The icon Green Arrow Box is illuminated to show when the pave...

Page 58: ...el level of greater than 10 Ared icon indicates that the Fuel Tank Status has a fuel level of 10 or less Right Side Button Icons Calibration Menu machine set up 20 Figure 4 6 is displayed adjacent to the top button Button 5 Navigation to the Main Calibration page is accomplished by pressing Button 5 Diagnostics Menu 21 Figure 4 6 is dis played adjacent to the second from the top button Button 6 Na...

Page 59: ...s the top of the screen They behave the same way on each screen and are activated by the engine and system messages Advanced Functions Screen Pressing 2 Advanced Functions button while either the Main Run 1 or Main Run 2 screen is displayed will navigate to the Advanced Functions display screen C 4 15 14 8 38 10 9 41 40 39 42 43 30 D B 44 45 Figure 4 11 Advanced Functions Screen ...

Page 60: ...ed System 4 Figure 4 11 Enabled Disabled is displayed by an icon on each side of the turn indicators The icon green auger will become animat ed when the system is enabled by utilizing the left hand and right hand switches for the feed system on the console panel The icon green auger will become un animated when the system is disabled NOTE It is NOT required to enable the LH or RH Feed Systems befo...

Page 61: ...he Screed Lower Float switch on the console panel The Screed Lower Float button is a momentary button that will lower the screed and put it into float mode when Button 5 is pressed Button 7 is not active for this display screen HOME 30 Figure 4 11 is displayed ad jacent to the bottom button Button 8 Navigation to the Main Run 1 screen is accomplished by pressing Button 8 25 26 27 28 29 30 Figure 4...

Page 62: ...ce chapter of this manual Master Switch Figure 4 14 Master Switch The master switch 2 must be in the ON position before the machine can be started The master switch can be accessed through an ac cess door in the hood on the right side of the opera tor platform NOTE Do not turn off the master switch when the engine is running The electrical system may be damaged Wait until the light above the switc...

Page 63: ...5 Shipping and Lifting Machine Date May 2020 Page 5 1 Operations Manual CR 820 T 5 SHIPPING AND LIFTING ...

Page 64: ...den damage is found after the carrier s rep resentative has gone do not continue to unpack or move the equipment Contact the carrier s local office and have the terminal manager or autho rized representative make an immediate personal inspection of the damage Obtain a written descrip tion of the damage and photos if available signed by the representative as proof of a valid claim If the purchaser ...

Page 65: ...e brakes should be used to stop the paver only in an emergency If the screed is removed carefully watch the augers to make sure they do not drag on the ground during loading or unloading All constructed ramps must be capable of support ing the total machine weight If screed is attached always ensure the screed is up and locked Remove all chains and binders from the paver frame Start the engine See...

Page 66: ...se the setting on the Paver Speed Control Knob 14 until the paver starts moving It is safer to use a slow speed while loading or unloading 9 Watch the area at the rear of the tractor to be sure that components do not drag on the ground 10 Back the machine off the trailer Preparation for Transport Do not set the screed on nails rivets or bolts These can cause damage to the screed bottom Chaining di...

Page 67: ...ntrol Panel 3 Use the frame raise switch 6 on the op erator s console to lower the rear of the paver as much as possible Figure 5 6 Front Tie down Point 4 Use chains and chain binders to the tie down points 4 in the front Figure 5 7 Rear Tie down Shackle 5 Connect chains and chain binders to the tie down shackles 1 at the rear of the paver ...

Page 68: ...5 Shipping and Lifting Machine Operations Manual CR 820 T Date May 2020 Page 5 6 Intentionally Left Blank ...

Page 69: ...6 Initial Setup and Adjustments Date May 2020 Page 6 1 Operations Manual CR 820 T 6 INITIAL SETUP AND ADJUSTMENTS ...

Page 70: ...n Place blocks on a flat level surface where the screed can be installed Attach a crane or other lifting device to the screed Lift the screed off the trailer and place it on the blocks Figure 6 1 Pull Arm Connection 1 Back the tractor up to the screed until the pull arms 1 on the tractor are aligned with the pull arms 2 on the screed 2 Bolt the screed pull arms to the tractor pull arms 3 Make the ...

Page 71: ...ectrical cable from the left hand screed control box to connector 5 d Main power electrical cable from the left hand screed control box to connector 6 e MOBA control electrical cable from the right hand screed control box to connector 7 f Hydraulic hoses from the center vibrator tees to the male and female connections 8 on the tractor g If the screed has electric heaters connect single receptor co...

Page 72: ...6 Initial Setup and Adjustments Operations Manual CR 820 T Date May 2020 Page 6 4 Intentionally Left Blank ...

Page 73: ...7 Standard Operating Procedures Date May 2020 Page 7 1 Operations Manual CR 820 T 7 STANDARD OPERATING PROCEDURES ...

Page 74: ...e raised to gain access to the engine for daily inspection The hood is raised using a hydraulic cylinder which is activat ed by the up button 1 behind the R H hood access door located on the front bulkhead Figure 7 2 Master Switch 1 Open R H hood access door to gain ac cess to battery switch and hood raise lever 2 Turn master battery switch to the on posi tion 2 Figure 7 2 3 Move and hold lever 1 ...

Page 75: ...ood Safety Latch Locked Figure 7 4 Hood Safety Latch Unlocked Figure 7 3 shows the center hood safety latch in the locked position Through the R H hood access door raise the center hood a bit to remove the weight from the safety latch then pull down on the release plate to put the latch in the unlocked posi tion Figure 7 4 Figure 7 5 Hood Raise Mechanism 1 After assuring all personnel are clear pr...

Page 76: ...ydraulic oil level and the fuel level f Inspect all steps hand holds and handrails for cleanliness g Inspect the hydraulic system for leaks and trash buildup h Be sure all covers and guards are firmly in place and inspect for damage and loose or missing bolts i Be sure all safety items decals guards walkways etc are in place and properly installed j Verify that all decals are properly adhered to t...

Page 77: ... that the keyswitch is on the left side console Set the console switches and controls as follows 11 Figure 7 8 Emergency Stop Switch Emergency Stop Switch Pulled out not ac tived twist to de activate Turn Key switch to the start position fully CW Starter will crank release when en gine starts If engine fails to start the keyswitch must be turned to the OFF position fully CCW and then turned back t...

Page 78: ...me 5 Lowering the Screed 6 To release the screed lock and lower the screed toggle the screed lock switch 2 inst cluster The screed will automatically lift while you hold the switch 7 While holding the switch toggle the screed lift float 1 inst cluster 8 Once the screed lock arm 1 7 10 has passed below the block off cam 2 7 10 on both sides you can release the screed unlock toggle Fume Recovery Sys...

Page 79: ... allows the speed of the fan to be adjusted To adjust the valve 1 Move ring 1 away from the knob 2 2 Rotate the knob to increase and decrease the fan speed Null the Screed Adjust the screed s angle of attack to 0 in relation to a specific depth Use boards that equal the desired loose mat depth The boards should be equal to the thickness of the loose or unrolled mat The number needed will de pend o...

Page 80: ...s quickly learn the exact amount of initial angle of attack needed for specific mix designs Joints Figure 7 14 Types of Joints There are two types of joints that are constructed in a paving operation longitudinal 1 and transverse 2 Proper construction of these joints is important not only in producing a smooth rideable surface but also in how they resist penetration of water air and other substanc...

Page 81: ...r chamber as this is the most common cause of creating a bump just after pulling off a joint If needed the corner areas on the ends of the screed should be hand filled to prevent force feeding an excessive high head of material in the center areas of the screed Move the paver forward slowly allowing the screed operator time to check and correct the depth if nec essary Set the feeder controls to AU...

Page 82: ...actor and screed This may cause the following problems Oil in the asphalt will cause the rubber to soften and reduce the durability Aggregate will abrade the rubber and shorten its life Asphalt material buildup in the undercar riage will cause additional tension Hydraulic Tunnel Figure 7 20 Hydraulic Tunnel Extended To help prevent asphalt from flowing down to the rear wheel two options are availa...

Page 83: ...erly the plates must have the bottom edge of the plate below the bottom edge of the machine frame bulkhead and be extended Make sure the plates are extended before paving begins Figure 7 22 Adjusting the Manual Material Re taining Plate Loosen the nuts 1 Slide the plate 2 out from the frame 3 Figure 7 23 Adjusting the Manual Material Re taining Plate Re tighten the nuts 1 to hold the plate in posi...

Page 84: ...llow Warn if both are ac tive Illuminated WTS Lamp Wait to Start Coolant Temp Illuminated Red if temp 230F Oil Pressure Illuminated Red is engine oil pres sure 15 PSI Engine must be running System Voltage Illuminates Yellow if system voltage 9 VDC Hydraulic Oil Temperature Illuminates yellow if hydraulic temp 240F Parking Brake Red is brake is set Alternates between green red when Auto Brake is en...

Page 85: ...ut to shut down After the shutdown the operator can re start but will only be able to run for 30 more sec onds before another shutdown The control system can show and record operation anomalies that present themselves as fault codes These codes will make troubleshooting easier The fault codes are recorded in the ECM They can be read using the micro controller Not all engine or control system anoma...

Page 86: ...e completely cleaned even if it was used for a short time Start cleaning at the truck hook push rollers and work your way to the rear of the machine cleaning the hopper wings slat conveyors hopper gates spreading augers screed bottom end gates strike offs etc Operate the slat conveyors during spray down to be sure all surfaces are cleaned Spray down the surfaces that have come in contact with asph...

Page 87: ...ompartment is full of electrical and hydraulic components which could be damaged by high pressure water Use a com mercial engine cleaning foam to remove dirt and grease from the engine compartment If spraying near electrical or hydraulic components is required cover the components before spraying Inducements The ECM is constantly monitoring the Aftertreatment system to verify that the engine exhau...

Page 88: ...gnores or cannot address the cause s of the Primary and Secondary Inducement s Final Inducement will be applied The ECM will automatically ramp down the en gine speed and then lock to Idle only Final Inducement begins with the illumination of the STOP for 2 minutes followed by a gradual ramp down to idle CAUSE TIME TO FINAL INDUCEMENT DEF Level 30 min after DEF Gage reads 0 DEF Quality 4 Hours or ...

Page 89: ...w soon after see next 2 slides Ideal Quality DEF is 32 5 1 5 Urea and 77 5 Water Quality is reported on the opera tor display as Urea DEF Fluid in the reservoir must meet ISO Standard 22241 1 a k a DIN 70027 The following conditions are optimal for maintaining DEF Quality and shelf life during prolonged transportation and storage Storage Temperature between 23 F and 77 F 5 C and 25 C Store in seal...

Page 90: ...main J1939 Bus to alert the operator Tampering Malfunction events include but are not limited to Disconnected malfunctioning DEF Tri Sen sor Blocked DEF Line or Dosing Valve Disconnected DEF Dosing Valve Disconnected Supply Module Disconnected NOx sensor s or Tempera ture Modules EGR Exhaust Gas Recirculation Valve malfunction Disconnected Coolant Level Sensor Any other hardware performance issues...

Page 91: ... and the run the engine for a few minutes When working to clear Faults Warnings be sure to power cycle the system after making repairs to ensure that the operator display refreshes the Ac tive Faults screen Best practice is to power down the unit prior to making repairs and power back up to verify Once the only Active Fault remaining is SPN 3714 FMI 31 run the engine for several min utes to clear ...

Page 92: ...hrottle from Low Idle to High Idle Power Cycle the machine This will clear SPN 3712 FMI 0 The final step is to run the machine for several minutes so that the SPN 3714 FMI 31 Clears ESC Exhaust System Clean ing Exhaust System Cleaning is an automatic process initiated by the ECM to reduce particulates and maintain efficiency of the Aftertreatment system Exhaust temperature will increase and the en...

Page 93: ...8 Emergency Procedures Date May 2020 Page 8 1 Operations Manual CR 820 T 8 EMERGENCY PROCEDURES ...

Page 94: ...park and ignite the hydrogen gas that is produced by the battery These pavers use a 12 Volt electrical system When jump starting or charging the paver make sure to use a 12 Volt power source Open the LH hood access door Connect the jumper cables to the power source Connect the positive cable 1 to the positive battery terminal or power terminal on the hood raise power pack motor Connect the negativ...

Page 95: ...enever it is unsafe to operate any piece of equipment When used as intended the lockout and tagout proce dure also protects personnel from energy stored in devices such as springs accumulators batteries hydraulic systems etc A lockout and tagout should be performed in the following situations Any time anyone is maintaining repairing lubricating or for whatever reason work ing on the equipment When...

Page 96: ... paver to collide with the tow ing vehicle Use a proper verified pulling device capable of pull ing at least 25 tons to tow the paver When manually releasing the brakes maintain a minimum of 350 psi 2413 kPa Do not exceed 750 psi 5171 kPa Attaching chains to the push roller frame or truck hook frame could result in serious and expensive damage Pulling the paver faster than 25 feet per minute can r...

Page 97: ...ear bulkhead right hand side Place a cap on the valve fitting to keep dirt out of the hydraulic system Attach a porta power a tee and a pressure gauge to the open hose end Pump the pressure up to at least 350 psi 2413 kPa to release the brakes The brakes can be reapplied by releasing the pressure at the porta power Figure 8 6 Bearing Covers Open the front conveyor bearing covers 6 Figure 8 7 Conne...

Page 98: ...8 Emergency Procedures Operations Manual CR 820 T Date May 2020 Page 8 6 Intentionally Left Blank ...

Page 99: ...9 Maintenance Date May 2020 Page 9 1 Operations Manual CR 820 T 9 MAINTENANCE ...

Page 100: ...ual Every 8 Service Hours or Daily Item Service Lube Daily Inspection Perform the steps listed in the Standard Oper ating Procedures chapter Fuel Level Check DEF Level Check Fuel Filter Water Separator Drain Hydraulic Tank Check oil level IS AW 68 Cooler Assembly Inspect Hydraulic Lines and Components Check Air Inlet Connections Check Engine Oil Check 15W 40 Engine Coolant Check 50 50 Mix Radiator...

Page 101: ...r loose troubleshoot the track hydraulic system Pump Drive Belts Check tension Match Height Assembly Lubricate EP1 or EP2 Extension Slope Assembly Lubricate EP1 or EP2 Spreading Auger Lubricate drive chains EP1 or EP2 Lubrication Lubricate grease points on depth cranks crown control and swivel seats EP1 or EP2 After First 150 Service Hours Item Service Lube Final Drive Change oil after the first 1...

Page 102: ...uid IS AW 68 Final Drive Replace oil 80W 140 Synthetic Spreading Auger Speed Reducer Replace oil 80W 140 Synthetic Every 2000 Service Hours Crankcase Ventilation Filter Replace filter DEF Tank Filter Replace filter Depending upon the conditions under which the paver is operated the DEF system may require servicing more often than every 2000 hours Yearly Item Service Lube Engine Coolant Drain the o...

Page 103: ... WARNING lamp will blink or flash when out of range conditions continue to worsen When the STOP lamp is illu minated the operator must pull to the side of the work area when it is safe to do so to reduce the possibility of engine damage Engine power and speed will be gradually reduced depending on the level of severity of the observed condition until the engine shuts down Hydraulic Fluid Reservoir...

Page 104: ...nd back to their respective pumps There is one supercharged auxiliary filter located on the left side of the paver underneath the after treatment This filters the oil going into the auxiliary pump when in stroke otherwise the oil is sent back to the tank Maintenance Procedures Unless a procedure requires the engine to be run ning perform the lockout and tagout procedure as described in the Emergen...

Page 105: ...ot and the contami nants are in suspension Operate the engine until the engine coolant tem perature reaches 140 F 60 C Shut the engine down and perform the lockout and tagout procedure Place a suitably sized container beneath the oil drain hose Disconnect the oil drain hose from the tractor frame and lower the hose down near the container Remove the oil drain plug 1 and allow the oil to drain into...

Page 106: ... belt length cracks that intersect with transverse cracks are not acceptable Replace the belt if it is frayed or has pieces of mate rial missing Check Engine Coolant Do not remove the radiator cap from a hot engine Wait until the temperature is below 120 F 49 C before removing the pressure cap Failure to do so can result in personal injury from heated coolant spray or steam Remove the filler cap s...

Page 107: ...out of the overflow Replace Engine Coolant Do not remove the radiator cap from a hot engine Wait until the temperature is below 120 F 50 C before removing the pressure cap Failure to do so can result in personal injury from heated coolant spray or steam Remove the filter cap slowly to re lieve coolant system pressure Do not add coolant to a hot engine Engine castings can be damaged Allow the engin...

Page 108: ...ing conditions will determine how often the cool er assembly needs to be inspected and cleaned If severe conditions exist or there are a lot of airborne contaminates it may be necessary to inspect and clean the cooler assembly more than once a day Check for damaged hoses and loose or damaged hose clamps Replace as needed Check the cooler for leaks and damaged or bent fins Repair as needed Check th...

Page 109: ...Aftertreatment Supply Module Heated DEF Lines DEF Lines Pressure Suction Return and the Supply Module are also electrical ly heated to thaw the DEF at very low tem peratures DEF Freezes 11 C 12 F Miscellaneous Flush DEF Tank and Replace Filter 1 5 Figure 9 13 DEF Tank Remove drain plug 1 and drain the DEF tank into a suitable container Figure 9 14 Header and Hoses Disconnect the hoses 2 going into...

Page 110: ...n place Intake air must be filtered to prevent dirt and debris from entering the engine and causing serious and expensive damage Do not attempt to clean a used element in any way Always discard the old element and install a new element Running the machine with an air cleaner that needs replacement does not allow the engine to get the proper amount of air to burn the fuel properly which reduces eng...

Page 111: ... hours This means that every second time that the primary filter element is replaced the secondary filter element will also be replaced Never operate the machine without an air cleaner with all elements in place Intake air must be filtered to prevent dirt and debris from entering the engine and causing serious and expensive damage Do not attempt to clean a used element in any way Always discard th...

Page 112: ...e Tighten or replace parts as necessary to make sure the air inlet system does not leak The air inlet system includes the piping from the air cleaner to the turbocharger and the piping from the turbo charger to the after cooler or inlet manifold depending on model Fuel System Check Fuel Level Keep away from sparks or open flame while work ing with fuel Figure 9 20 Fuel Gauge Check the fuel level o...

Page 113: ... the filter sump of water until clean fuel is vis ible Close the valve Check the valve after draining to be sure it does not leak Replace Fuel Filter Water Separa tor When installing a replacement filter element keep in mind that overtightening may distort the threads or damage the filter element Figure 9 22 Fuel Filter Water Separator Clean the area around the filter head Remove the filters Clean...

Page 114: ...eached on the sight glass Do not add beyond this point as overfilling the hydraulic tank does not leave room for thermal expansion when the oil is at running temperature Excess oil will be blown out the vented fill cap into the engine bay Clean Strainer and Replace Hydraulic Fluid Overfilling the hydraulic tank does not leave enough room in the hydraulic system for thermal expansion when the oil i...

Page 115: ...taminants off the outside of the strainer as it is removed from the manifold Clean the strainer with compressed air Solvent can be used if needed Install the strainer in the suction manifold Check the cover seals If necessary replace them Install the covers Figure 9 28 Hydraulic Tank Fill Opening Fill the tank through fill opening 6 with clean fil tered hydraulic fluid Loosen the case like fitting...

Page 116: ...a thin film of clean hydraulic oil to the threads on the head and to the element gasket Install the filter by hand until the element touches the head Turn the element 3 4 turn more to seat the element Replace Auxiliary Pump Filter Figure 9 31 Auxiliary Pump Filter Remove the filter element 2 Clean the head where the filter element seats Apply a thin film of clean hydraulic oil to the threads on th...

Page 117: ...here are two pump drive belts This procedure must be performed for both belts Operate the machine for at least 2 hours to bring the machine up to operating tem perature Stop the engine and perform the lockout and tagout procedure Raise the hood 1 1 Figure 9 32 Access Covers Loosen the belt access cover bolts then rotate the covers 1 until the belts are visible 5 10 15 20 25 30 1 2 INCHES 5 10 15 2...

Page 118: ...the scale Remove the tester Read the belt deflection force in pounds at the small o ring Compare the value with the table below Ref Table 9 1 If the value is outside the force listed in the table the belt must be re tensioned See the follow ing steps in this procedure Temperature Force Deflection At operating temperature 18 lbs 8 2 kg Minimum 1 4 in 6 4 mm 20 lbs 9 1 kg Maximum Cold Equipment 8 lb...

Page 119: ...Sulfuric acid in batteries is a poison and could cause severe burns Avoid contact with skin eyes and clothes When you work around batteries pro tect your eyes and face from battery fluid and ex plosion When removing the battery cables always remove the negative terminal first then the positive termi nal This will reduce the chance of sparking Check the battery terminals for corrosion buildup and t...

Page 120: ...k plug 2 is 90 down from the fill plug Remove the level check plug The oil level should be even with the bottom of the level check plug hole Verify that there is no hydraulic oil in the final drive housing before adding gear oil Hydraulic oil in this housing indicates leakage from the brake or hy draulic drive motor Add more oil if the oil level is low Remove the fill plug 1 Add oil to bring the l...

Page 121: ...the level check plug hole Reinsert both the level check plug and the fill plug Slat Conveyor System Conveyor Bearings Lubricate the conveyor bearings on each conveyor with Lithium base type EP Grade 2 grease Figure 9 40 Front Conveyor Bearing Fittings Figure 9 41 Inner Rear Conveyor Bearing Fit tings Figure 9 42 Outer Rear Conveyor Bearing Fit tings Two front conveyor bearing fittings 1 on each si...

Page 122: ...emove the slack from the chain but do not over tighten Be sure that the chain can move slightly under thumb pressure After the chain has been tensioned prop erly tighten the jam nut Repeat steps 3 and 4 for the other drive chain Replace the cover Lubrication Figure 9 44 Spreading Auger Bearing Lubricate the Spreading Auger Bearings one on left and one on right 1 Clean Truck Hitch The truck hitch s...

Page 123: ...e Log located in the Troubleshooting chapter of this manual Clean Fume Recovery System Figure 9 46 Fume Recovery Hood Section Figure 9 47 Fume Recovery System Fan 1 Check all hoses and for cracks cuts dents or col lapsed spots Cuts or cracks may be repairable with duct tape Repair or replace as needed Check the interior surfaces of hoses and hoods 2 for asphalt buildup Clean the by soaking in solv...

Page 124: ...ful to not damage or cut it when cleaning Check the track alignment Rubber track undercarriage component alignment is very important to the life of the track An easy quick check is to inspect the track center lugs Figure 9 50 Track Center Lugs If one side is worn more than the other side the following conditions could exist asphalt build up on the track inner surface road crown track tensioning et...

Page 125: ...chine Data Machine Serial Number Hour Meter Reading Date of Track 1st Use Right Track Left Track Track Width Number of Pitches Pitch 6 in 15 24 cm 6 in 15 24 cm Track Serial Number Figure 9 52 Track Record Check Hood Raise Reservoir Oil Level Figure 9 53 Hood Raise Reservoir Make sure hood raise reservoir 1 is full when hood is fully lowered or about full when fully open Do not overfill the tank a...

Page 126: ...9 Maintenance Operations Manual CR 820 T Date May 2020 Page 9 28 Intentionally Left Blank ...

Page 127: ...10 Storage Date May 2020 Page 10 1 Operations Manual CR 820 T 10 STORAGE ...

Page 128: ...n wood not concrete Be sure all panel lids and covers are in place Close them tightly to prevent water entry Enclose consoles in a protective cover Leave the bottom of the wrap open to pre vent condensation inside Remove all books and literature from the tool boxes and store them inside the office or with other stored components Refer to the engine manufacturer s specifi cations for protection of ...

Page 129: ...Intentionally Left Blank ...

Page 130: ...Printed in U S A BOMAG Americas Inc 125 Blue Granite Parkway Ridgeway South Carolina 29130 U S A 800 782 6624 ...

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