Asphalt Paver Technical Manual

PAVER TECHNICAL MANUAL

49999-150 (12/04)

PAVER TECHNICAL MANUAL NOTICE! This manual is intended to assist with the trouble-shooting and repair of Terex Cedarapids pavers and screeds. It is a guide only and NOT all-inclusive. ALWAYS refer to the specific serial numbered assembly for your particular machine.

24 Hour Service Number (800) 821-5600

Serial Number Date 3500 ......................................... 9/35 4000 ......................................... 4/37 4500 ......................................... 5/39 5500 ....................................... 12/41 6000 ......................................... 4/42 7000 ....................................... 11/43 7500 ....................................... 12/44 8500 ......................................... 8/45 9500 ......................................... 7/46 10500 ......................................... 3/47 11500 ......................................... 6/48 12000 ......................................... 4/49 12500 ......................................... 2/50 13000 ......................................... 1/51 14500 ......................................... 7/52 15000 ......................................... 7/53 15650 ......................................... 6/54 16400 ......................................... 6/55 17300 ......................................... 3/56 18900 ......................................... 6/57 19900 ......................................... 6/58 20920 ......................................... 3/59 22260 ......................................... 6/60 22850 ......................................... 1/61 23650 ......................................... 1/62 24500 ......................................... 1/63 25400 ......................................... 1/64 26300 ......................................... 1/65 27400 ......................................... 1/66 28550 ......................................... 1/67 29540 ......................................... 1/68 30300 ......................................... 1/69 31000 ......................................... 1/70 31750 ......................................... 1/71 32300 ......................................... 1/72 32870 ......................................... 1/73 33450 ......................................... 1/74 16093 (12/04)

Serial Number/Date Record Approximate Manufacturing Dates Serial Number Date 34120 ......................................... 1/75 34720 ......................................... 1/76 35190 ......................................... 1/77 35790 ......................................... 1/78 36326 ......................................... 1/79 37180 ......................................... 1/80 37910 ......................................... 1/81 38460 ......................................... 1/82 38760 ......................................... 1/83 39090 ......................................... 1/84 39420 ......................................... 1/85 39810 ......................................... 1/86 40290 ......................................... 1/87 40918 ......................................... 1/88 41526 ......................................... 1/89 42195 ......................................... 1/90 42772 ......................................... 1/91 43248 ......................................... 1/92 43637 ......................................... 1/93 44062 ......................................... 1/94 44630 ......................................... 1/95 45400 ......................................... 1/96 45735 ......................................... 1/97 47214 ......................................... 1/98 48187 ......................................... 1/99 48729 ......................................... 7/99 49198 ....................................... 12/99 50434 ....................................... 12/00 51203 ....................................... 12/01 51800 ....................................... 12/02 52361 ....................................... 12/03 52500 ....................................... 12/04 TIER II Machines 60001 thru 60005 ..................... 12/02 60055 ....................................... 12/03 60158 ....................................... 12/04

Hydraulic Hose Assembly Coding

Technical Manual

Coding System for Re-useable End Type Hydraulic Hose Assemblies

HOSE TYPE CODE 5- Parker Type 421 or Equal 6- Parker Type 381 or Equal 7- Parker Type 741 or Equal 8- Parker Type 341 or Equal 9- All Types NOT Designated Above

HOSE SIZE CODE 0- 1/4” I.D.

5- 1-1/4” I.D.

1- 3/8” I.D.

6- 1-1/2” I.D.

2- 1/2” I.D.

7- 2” I.D.

3- 3/4” I.D.

8- Not Assigned

4- 1” I.D.

9- Hose Sizes Not Listed Such As 7/16” I.D.

7550 THRU 7599 ARE FOR HYDRAULIC HOSE ASSEMBLIES. THE HOSE ASSEMBLIES ARE CODED PER THE FOLLOWING SYSTEM.

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Technical Manual

Coding System for Re-useable End Type Hydraulic Hose Assemblies

HOSE END CLAMP 1- Male Pipe 2- Flareless Swivel (Female) 3- JIC (37°) Swivel- Straight 4- JIC (37°) Swivel- 45° Elbow 5- JIC (37°) Swivel- 90° Elbow 6- Flange Head- 45° Elbow 7- Flange Head- 90° Elbow 8- Not Assigned 9- Not Assigned 0- Hose Ends NOT Listed Above

HOSE ASSEMBLY VARIATIONS No number listed- hose assemblies with both ends the same size as the hose and at least one straight end. -01 thru 49- variations of standard hose: Example: Hose end or ends of a different size than the hose I.D., hose end requiring orietation such as both ends being elbows, etc. -50- standard hose except 1/2” longer than the length code would indicate (See Note #1) -51 thru 99- same as 01 thru 49 except hose length would be 1/2” longer than length code would indicate. (See Note #1)

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Technical Manual

Coding System for Re-useable End Type Hydraulic Hose Assemblies NOTE #1 On hose lengths longer than 24” the 1/2” length increments should not be used except in very special situations. Generally speaking, cutting lengths are not accurate enough to warrant calling for hose in 1/2” increments. Under 24” the 1/2” length may be used when necessary but should be avoided if possible. EXAMPLES 1/2” I.D. #301 hose 69” long with 1/2” male pipe fitting on one end and 1/2” JIC (37) swivel 45° elbow on the other end, part # would be 7562-069-14. The same hose but with a 3/8” male pipe fitting instead of 1/2” would be 7562-069-14-01. The same hose but with a 3/8” male pipe fitting and 69-1/2” long would be 7562-069-14-51. The same hose with 90° flange head elbows would show the orientation of the elbows to each other and would be 7562-069-77-01. Each hose number assignment should be cross-checked against the aperture card file to prevent duplication of part number assignments and/or duplication of hose drawings.

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Technical Manual

Coding System for Crimped Type Hydraulic Hose Assemblies

CODE NUMBER ASSIGNMENTS HOSE TYPE CODE 1&2. Not Assigned 3.

SAE100R4 Suction Hose

4.

Medium Pressure

SAE100R5 Single wire braid-cotton braid cover

5.

Medium Pressure

SAE100R1 Single Wire Braid/ Abrasion Resistant Synthetic Cover

6.

High Pressure

SAE100R2 Two Wire Braid/ Abrasion Resistant Synthetic Cover

7.

Very High Pressure

SAE100R9 Four Wire Spiral/ Abrasion Resistant Synthetic Cover

8.

Extremely High Pres. Hose Rated Greater Than SAE100R9

9.

All Hose Types Not Assigned

HOSE SIZE CODE 0. 1/4” I.D.

5.

1-1/4” I.D.

1.

3/8” I.D.

6.

1-1/2” I.D.

2.

1/2” I.D.

7.

2” I.D.

3.

3/4” I.D.

8.

Not Assigned

4.

1” I.D.

9.

Hose Sizes Not Listed (Such As 7/16” I.D.)

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Technical Manual

Coding System for Crimped Type Hydraulic Hose Assemblies HOSE END CODE 1. Male Pipe 2. Not Assigned 3. JIC (37°) Swivel- Straight 4. JIC (37°) Swivel- 45° Elbow 5. JIC (37°) Swivel- 90° Elbow (SAE Short Drop) 6. Flange Head- 45° Elbow Code 61 7. Flange Head- 90° Elbow Code 61 8. JIC (37°) Swivel- 90° Elbow (SAE Long Drop) 9. Flange Head- Straight 0. Hose Ends Not Listed Above HOSE ASSEMBLY VARIATIONS No number listed- hose asemblies with both ends the same size as the hose and at least one straight end. 01 thru 49- variations of standard hose Examples: Hose end or ends of a different size than the hose I.D., hose end requiring orientation such as both ends being elbows, etc. 50- standard hose except 1/2” longer han the length code would indicate. (See Note #1) 51 thru 99- same as 01 thru 49 except hose length code would be 1/2” longer than length code would indicate. (See Note#1) NOTE #1 On hose lengths longer than 24” the 1/2” length increments should not be used except in very special situations. Gnerally Speaking, cutting length are not accurate enough to warrant calling for hose in 1/2” increments. Under 24” the 1/2” length may be used when necessary but should be avoided if possible.

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Technical Manual

Coding System for Crimped Type Hydraulic Hose Assemblies

ANGULAR ORIENTATION READING CLOCKWISE FROM 0° TO 360° SHOW INLINE ORIENTATION AS 0° EXAMPLES: 1/2” I.D. :Type 5 hose 69” long with 1/2” male pipe fitting on one end and 1/2” JIC (37°) swivel 45° elbow on the other end, part number would be 7652-069-14. The same hose but with a 3/8” male pipe fitting instead of 1/2” would be 7652-069-14-01. The same hose but with a 3/8” male pipe fitting and 69-1/2” long would be 7652-069-14-51. The same hose with a 90° flange head elbows would show the orientation of the elbows to each other and would be 7652-069-77-01. Each hose number assignment should be cross-checked against the aperture card file to prevent duplication of part number assignments and/or duplication of hose drawing.

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Rubber Track Operating Hints

Technical Manual

Rubber Track Operating Hints

Rubber Track Operating Hints

Do Not Allow Asphalt Build-up on Track

The following are some specific considerations for operation of asphalt pavers equipped with rubber tracks. While not all-inclusive, following these recommendations should reduce the risk of problems and improve rubber track durability and reliability.

During paving, asphalt sometimes flows down to the rear drive wheel and become packed between the track and wheel. This may cause the following problems: •

Oil in the asphalt will cause the rubber in the track to soften and reduce the durability.

•

Aggregate will abrade the rubber in the track and shorten its life.

•

Asphalt material build-up in the undercarriage will cause additional tension on the track.

Asphalt Build-up May Cause........

Guide Crush

Material retaining plates retracted will allow material to carry back around to tracks.

Guide Wear

Extend plates to prevent this.

Inner Rubber Wear

Figure 1 Asphalt on Track & Wear 22762 (12/04)

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Rubber Track Operating Hints

Technical Manual

Rubber Track Operating Hints Proper Installation of Material Retaining Plates Machines are shipped with the material retaining plates as shown in (Figure 2). To work properly, the plates must have the bottom edge of the plate below the bottom edge of the machine frame bulkhead and be extended.

Before paving begins, loosen nuts, slide plate out from frame and re-tighten nuts to hold plate in position. (Figure 3)

Material retaining plates repositioned.

Figure 3

Figure 2

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Rubber Track Operating Hints

Technical Manual

Rubber Track Operating Hints Maneuvering On Hot Asphalt Pavers are not normally operated on newly paved hot asphalt as it will damage the surface of the mat. There may however be certain conditions when this becomes unavoidable. If it is necessary to drive on newly paved asphalt, be aware this could be problematic.

De-tracking Damage

Temporary De-tracking

Rubbing Marks on Frame

Figure 4 De-tracking

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Rubber Track Operating Hints

Technical Manual

Rubber Track Operating Hints Generally, “de-tracking” occurs when the paver turns. If rubbing marks are noted on track frame, check track inner surfaces for signs of scarring caused by temporary de-tracking. To avoid “detracking”, it is recommended: •

Do not turn on or near hot asphalt. Move to a cold area and turn there. If turning on the hot asphalt is necessary, use forward as much as permissible and keep the turn gradual in as large an arc as possible. Maneuvering should be done at as slow a speed as possible.

•

Do not park on hot asphalt. High temperature can deteriorate the track rubber. It is recommended to remain on the hot area of asphalt no longer than twenty (20) minutes. Figure 5 Do Not Park On Hot Asphalt

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Rubber Track Operating Hints

Technical Manual

Rubber Track Operating Hints Maneuvering On Uneven Surface

Caution - If a turn is attempted on an edge, track damage or “de-tracking” could occur.

Uneven terrain such as curbs, concrete ridges or joints of paved and unpaved surfaces (step in elevation) may affect machine maneuverability. One concern is the stress concentration caused by the sharp edges of the surface and another is when a track is parallel to an edge. (Figure 6)

Paver Edge of Mat Manhole

Figure 6 Steps in Elevation & Uneven Surfaces

•

Do not turn on or near sharp edges of uneven surfaces. It is best to make a turn while on an even surface. If a turn is made with a portion of the track on an edge or the track comes into contact with an edge during the turn, it could cause a cut, tear, or even “detracking”. If this situation is unavoidable, keep the turn gradual in as large an arc as possible, at slow speed, in forward and with a spotter to watch the track safety.

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•

Do not approach a step in elevation at a sharp angle. If it is necessary to move from one level of elevation to another, it is recommended the approach angle should be more than 45 degrees. The best method is to go perpendicular to it.

•

Do not park on a step in elevation. When parking, make sure the tracks are not resting on an edge or any sharp object. This may cause damage to the track. Rubber Track Operating Hints

Technical Manual

Rubber Track Operating Hints

Tearing

Chunking

Figure 7 Damage From Steps in Elevation & Uneven Surfaces

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Rubber Track Operating Hints

Technical Manual

Rubber Track Operating Hints Maintenance of Track

•

To maintain and preserve the life of the rubber track it is important to follow these recommendations: •

Do not use solvents to wash the rubber track. Solvents including kerosene, gasoline, diesel fuel, or oils cannot be used to wash the surface of track rubber. The track rubber absorbs these solvents and will gradually soften and reduce its durability. Soap and water are recommended for cleaning the rubber track.

Covering track for long term outdoor storage. Rubber is affected by exposure to sunlight (ozone). Covering the track with something like a vinyl sheet if the machine is idle for an extended length of time, such as over Winter, will help keep the surface in good condition. This is especially true where the rubber is bent and stretched around wheels.

NOTICE If you scrape the rubber track surface to clean it, be careful to not damage or cut it when cleaning. Figure 8 Cover Track for Outdoor Storage

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Rubber Track Operating Hints

Technical Manual

Rubber Track Operating Hints •

Releasing track tension for long term storage. As is true for covering the track, releasing the track tension when the machine is idle for an extended length of time, such as over Winter, will prolong its life.

.

Track Tension Valve Charge Cartridge

Test Port

NOTICE Before releasing track tension, make sure machine is parked on level ground. Release 300 Series Rubber Track Tension Track Tension Valve Discharge Cartridge

1) Shut off engine and remove key from ignition. 2) Loosen jam nut on track tension valve discharge cartridge (Figure 9). 3) Insert an allen wrench into the adjusting screw, slowly turn it counter-clockwise to open the shut-off valve and release hydraulic pressure.

Track Tension Valve

Figure 9 Release 300 Series Rubber Track Tension

4) Insert an allen wrench into the adjusting screw on the discharge valve cartridge and slowly turn it clockwise to close the valve. 5) Tighten jam nut on track tension valve discharge cartridge (Figure 10). 6) Repeat for the other track. The 300 series pavers will require tracks to be retensioned after removal from long term storage. This is not done automatically, see procedure in Operation and Maintenance Manual.

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Rubber Track Operating Hints

Technical Manual

Rubber Track Operating Hints Release 400 & 500 Series Rubber Track Tension

4) Insert an allen wrench into the adjusting screw and turn it clockwise to close the valve.

1) Shut off engine and remove key from ignition. 5) Tighten jam nut on tension release valve cartridge (Figure 10).

2) Loosen jam nut on tension release valve cartridge (Figure 10).

6) Repeat for the other track. 3) Insert an allen wrench into the adjusting screw, slowly turn it counter-clockwise to open the valve and release hydraulic pressure.

The 400 and 500 series pavers will require the tracks to be re-tensioned after removal from long term storage. They are automatically tensioned when the engine is started. See procedure in Operation and Maintenance Manual.

Tension Release Cartridge

Figure 10 Release 400 & 500 Series Rubber Track Tension

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Rubber Track Operating Hints

Technical Manual

Rubber Track Operating Hints •

4) Periodically check that any steel cable or ply cord are not exposed.

Check 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 11) If one side is worn more than the other side, one or more of the following conditions could exist. Factors such as asphalt build-up on the track inner surface, road crown, track tensioning, etc. If any of the above is present, correct the situation before excessive track wear occurs.

5) Periodically check that track is properly tensioned. A loose track could cause detracking. (Refer to Tension information in the Operation and Maintenance Manual.

Guide Lug Wear on One Side

Figure 12 Rubber Track Identification

You may use the following table to record the information off the tracks on your machine. Figure 11 Rubber Track Alignment

Data •

Visual Inspection. Unlike pneumatic tires, the rubber track is not as sensitive to chippings and cracks on the surface unless they extend to the separation of rubber from belt. The rubber track is not a 100% maintenance free product. The following items will be helpful to maintain and inspect your rubber tracks:

Left

6 inches

6 inches

Machine Serial Number Hour Meter Reading Date of Track 1st Use Track Width

1) Record track serial numbers.

Number of Pitches

2) Record the date and hour meter reading when you mount tracks on machine.

Pitch Track Serial Number

3) Periodically check condition of tread, guide lugs, and inner surface for wear, cracks, chipping and chunking. 22762 (12/04)

Right

Table 12 - 1 Rubber Track Data 10

Rubber Track Operating Hints

PAVER TECHNICAL MANUAL

300 Series & 411 Electrical Section

Technical Manual

A Terex Company

Table of Contents Grayhound 300 Series/CR411 Component Location Maps ......................................................................................... 1 - 10 Engine Starting System .................................................................................................... 11 Charging System .............................................................................................................. 12 Throttle & Fuel .......................................................................................................... 13 - 14 Engine Start & Fuel - Elite Engine ................................................................................... 15 Horn .................................................................................................................................. 16 Gauges .............................................................................................................................. 17 Lights ................................................................................................................................ 18 Brakes ............................................................................................................................... 19 Travel/Pave (P2) System CR361 ...................................................................................... 20 Front Wheel Assist CR351/CR411 .................................................................................. 21 Travel Control CR351/CR411 .................................................................................. 22 - 24 Travel Control & Steer Assist - Rubber Tire Pavers 1999 & After........................... 25 - 27 Travel Control Adj. Procedure-3 Pot Controller Grayhound Tire Pavers ................. 28 - 29 Travel Control Adj. Procedure-3 Pot Controller Grayhound Track Pavers .............. 30 - 32 Travel Control Adj. Procedure-4 Pot Controller Grayhound Tire Pavers ................. 33 - 34 Differential Lock CR351/CR411...................................................................................... 35 Steer Assist CR351/CR411 ....................................................................................... 36 - 37 LH Travel Speed Control CR361 .............................................................................. 38 - 39 RH Travel Speed Control CR361 .............................................................................. 40 - 41 Travel Control Adj. Procedure-4 Pot Controller Grayhound Track Pavers .............. 42 - 44 Susmic 10 Dual Path Control Calibration Procedures............................................... 45 - 49 Hopper .............................................................................................................................. 50 Truck Hitch (Optional) ..................................................................................................... 51 Frame Raise CR351/CR411 ............................................................................................. 52 LH Flow Gate ................................................................................................................... 53 RH Flow Gate ................................................................................................................... 54 Material Flow Indicators 1999 & Before .................................................................. 55 - 56 Material Flow Indicators 1999 & After ..................................................................... 57 - 58 Screed Lift ........................................................................................................................ 59 Screed Assist .................................................................................................................... 60 Power Main Crown ........................................................................................................... 61 Vibrators ........................................................................................................................... 62

300 Series & CR411 Electrical Troubleshooting

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A Terex Company

Table of Contents Grayhound 300 Series/CR411 LH Hydraulic Strike-Off Extend ...................................................................................... 63 RH Hydraulic Strike-Off Extend ...................................................................................... 64 LH Hydraulic Strike-Off Slope ........................................................................................ 65 RH Hydraulic Strike-Off Slope ........................................................................................ 66 LH Match Height .............................................................................................................. 67 RH Match Height ............................................................................................................. 68 LH Main Burner #1 .......................................................................................................... 69 RH Main Burner #2 .......................................................................................................... 70 LH Ext. Burner #3 ............................................................................................................ 71 RH Ext. Burner #4 ............................................................................................................ 72 Rear Frame Compensator Adjustment ............................................................................. 73 Remote Oil Cooler Motors ............................................................................................... 74

300 Series & CR411 Electrical Troubleshooting

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A Terex Company

Component Location Map Fastach 8 & 10

2

3

1

1 ........... Screed burner fan and glow plug 2 ........... Controls for glow plugs, fans and horn 3 ........... Burner and spray down control valves

300 Series & CR411 Electrical Troubleshooting

1

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A Terex Company

Component Location Map Fastach II

2

Cedarapids EXTEND

FEED OVER RIDE

STOP

SLOPE

MATCH

HEIGHT

BERM

TOWPOINT MAN MAN SETUP AUTO HORN

Cedarapids EXTEND

FEED OVER RIDE

STOP

SLOPE E TEMPERATUR RH MAIN

MATCH

RH EXT

HEIGHT LH MAIN LH EXT

CONTROL

HEAT

OUTLET

HEAT

OUTLET

HEAT

HEAT HEAT

BERM

GENERATOR ON

OFF

ON

OFF

TOWPOINT MAN MAN SETUP AUTO HORN

HORN

CROWN E INCREAS E DECREAS

1

1 ........... Screed Heater Control Panel 2 ........... Screed Generator

300 Series & CR411 Electrical Troubleshooting

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A Terex Company

Component Location Map Stretch 16 & 18

2

3

1

1 ........... Screed burner fan and glow plug 2 ........... Controls for glow plugs, fans and horn 3 ........... Burner and spray down control valves

300 Series & CR411 Electrical Troubleshooting

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Component Location Map Grayhound 300 Series/CR411

DIN Connector

Earlier Version Travel Controller

Low Threshold Reverse Maximum Pot Forward Maximum Pot Manual Override

DIN Connector Current Version Travel Controller MINIMUM Forward Pot

MINIMUM Reverse Pot

MAXIMUM Forward Pot

MAXIMUM Reverse Pot

300 Series & CR411 Electrical Troubleshooting

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A Terex Company

Component Location Map Grayhound 300 Series/CR411 L4

L2 L1

L3

L5

L6

Front Bulkhead L17 L9

L12

L8 L7

L16 L11

L13

L10

Rear Bulkhead

L14 L15

L1 ......... Slope sensor L2 ......... Front wheel assist L3 ......... LH pull point solenoid L4 ......... Truck hitch solenoid L5 ......... LH material flow gate L6 ......... RH material flow gate L7 ......... Main electrical junction box L8 ......... Hopper wing solenoid L9 ......... RH pull point solenoid L10 ....... Screed lift solenoid L11 ....... Frame raise solenoid L12 ....... Brake solenoid L13 ....... Vibrator solenoid L14 ....... LH feed sensor L15 ....... RH feed sensor L16 ....... Travel/Pave solenoid L17 ....... Burner/Spraydown pump & motor

300 Series & CR411 Electrical Troubleshooting

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A Terex Company

Component Location Map 1st Generation Version Grayhound 300 Series Analog Display 24 23 22 21 20 19 18 17 16 15 1 2 3 4 5 6 7 8 9

12 14

13 10

11

1 ........... Engine breaker: 15 amp 2 ........... Screed breaker: 15 amp 3 ........... Control breaker: 15 amp 4 ........... F/G/S breaker: 15 amp 5 ........... Spraydown breaker: 15 amp 6 ........... Light breaker: 15 amp 7 ........... Flasher breaker: 15 amp 8 ........... Gate breaker: 30 amp 9 ........... Burner breaker: 50 amp 10 ......... Key switch 11 ......... K2 relay 12 ......... K22 relay

300 Series & CR411 Electrical Troubleshooting

13 ......... RH auger/conveyor proportional module 14 ......... LH auger/conveyor proportional module 15 ......... K3 relay 16 ......... K4 relay 17 ......... K5 relay 18 ......... K6 relay 19 ......... K15 relay 20 ......... K16 relay 21 ......... K17 relay 22 ......... K18 relay 23 ......... Spare relay 24 ......... Flasher relay

6

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A Terex Company

Component Location Map 1st Generation Version Grayhound 300 Series Analog Display 10

9

8

11 12 20 21 30 31

7

6

5

13

16

19

18

14 15 17

22 29

23

24

4 3 2

1

25 26 27

28

36

32

37

33 34

35

28 30 31 29

16

4

1 ............. Travel control 2 ............. Differential lock switch 3 ............. Travel speed pot 4 ............. Rear frame compensator switch 5 ............. Screed assist switch 6 ............. Screed lift switch 7 ............. Screed vibrator switch 8 ............. Engine stop/start/run switch 9 ............. RH conveyor switch 10 ........... LH conveyor switch 11 ........... RH conveyor speed pot 12 ........... LH conveyor speed pot 13 ........... Permissive start switch 14 ........... LH screed extension switch 15 ........... RH screed extension switch 16 ........... Frame raise switch 17 ........... Steer assist switch 18 ........... Flasher switch

300 Series & CR411 Electrical Troubleshooting

19 ........... RH flow gate switch 20 ........... LH flow gate switch 21 ........... Hopper wing switch 22 ........... Truck hitch switch 23 ........... Light switch 24 ........... Travel range switch 25 ........... Brake switch 26 ........... Horn switch 27 ........... Throttle switch 28 ........... Audible alarm silence switch 29 ........... Low engine oil pressure indicator light 30 ........... RH mix no flow indicator light 31 ........... LH mix no flow indicator light 32 ........... Oil temperature gauge 33 ........... Voltmeter 34 ........... Fuel level gauge 35 ........... Tachometer 36 ........... Water temperature gauge 37 ........... Oil pressure gauge 7

22478 (11/00)

Technical Manual

A Terex Company

Component Location Map 2nd Generation Version Grayhound 300 Series Analog Display 23 22 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9

13

10

11

12

1 ........... Engine breaker: 15 amp 2 ........... Screed breaker: 15 amp 3 ........... Control breaker: 15 amp 4 ........... F/G/S breaker: 15 amp 5 ........... Spraydown breaker: 15 amp 6 ........... Light breaker: 15 amp 7 ........... Flasher breaker: 15 amp 8 ........... Gate breaker: 30 amp 9 ........... Burner breaker: 50 amp 10 ......... Key switch 11 ......... K2 relay 12 ......... Cooler breaker: 50 amp

300 Series & CR411 Electrical Troubleshooting

13 ......... Feed Interface Module 14 ......... Cooler relay 15 ......... K3 relay 16 ......... K4 relay 17 ......... K5 relay 18 ......... K6 relay (flasher) 19 ......... K15 relay 20 ......... K16 relay 21 ......... K17 relay 22 ......... K18 relay 23 ......... K22 relay

8

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Technical Manual

A Terex Company

Component Location Map 2nd Generation Version Grayhound 300 Series Analog Display

10

9

8

7

6

13 20

19

18

21 30 31

22 29

23

5

4 3 2

1

16 14 15 25 26 27

24

28

36 37

32

35

33 34

28 30 31 29

16

4

1 ............. Travel control 2 ............. Steer assist switch 3 ............. Travel speed pot 4 ............. Differential lock switch 5 ............. Screed assist switch 6 ............. Screed lift switch 7 ............. Screed vibrator switch 8 ............. Engine stop/start/run switch 9 ............. RH conveyor switch 10 ........... LH conveyor switch 11 ........... N/A 12 ........... N/A 13 ........... Permissive start switch 14 ........... LH screed extension switch 15 ........... RH screed extension switch 16 ........... Frame raise switch 17 ........... N/A 18 ........... Flasher switch

300 Series & CR411 Electrical Troubleshooting

19 ........... RH flow gate switch 20 ........... LH flow gate switch 21 ........... Hopper wing switch 22 ........... Truck hitch switch 23 ........... Light switch 24 ........... Travel range switch 25 ........... Brake switch 26 ........... Horn switch 27 ........... Throttle switch 28 ........... Audible alarm silence switch 29 ........... Low engine oil pressure indicator light 30 ........... RH mix no flow indicator light 31 ........... LH mix no flow indicator light 32 ........... Oil temperature gauge 33 ........... Voltmeter 34 ........... Fuel level gauge 35 ........... Tachometer 36 ........... Water temperature gauge 37 ........... Oil pressure gauge 9

22478 (11/00)

Technical Manual

A Terex Company

Component Location Map Grayhound 300 Series/CR411

Throttle Solenoid

Alternator Murphy Temp Sensor

Engine Temp Sensor

Engine Oil Pressure Sensor

RPM Pickup

Starter Solenoid

300 Series & CR411 Electrical Troubleshooting

K2 Starter Relay

Starter

10

22478 (11/00)

Technical Manual

A Terex Company

Engine Starting System Grayhound 300 Series Analog Display Grayhound CR411

ENGINE DOES NOT START Main key switch ON Brake switch ENGAGED Travel switch in NEUTRAL position Control circuit breaker SET Stop/Start switch held in START position Permissive start switch held closed

ENGINE DOES NOT CRANK Check for low battery voltage, loose starter connections or faulty starter. If no voltage 1 to 3 ......... 20 to 3 ........ 21 to 3 ........ 13 to 3 ........ 14 to 3 ........ 16 to 3 ........ 15 to 3 ........ 2 to 3 .........

Defective main key switch. Defective or tripped engine circuit breaker. Defective main key switch. Defective engine start/stop switch. Defective brake switch. Limit switch 3 on LH travel switch defective. (Track) Limit switch 3 on RH travel switch defective. Defective starter relay (K2).

If voltage, check starter motor.

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Charging System Grayhound 300 Series Analog Display Grayhound CR411

ALTERNATOR NOT CHARGING (12.5 Vdc or less at battery) Main key switch ON Engine running at FULL THROTTLE Voltage should be 13.5 Vdc to 15.5 Vdc from 1 to 3 If no voltage 1 to 3 .......... If no voltage or high voltage (>16 Vdc), defective main key switch or wiring. 20 to 3 ........ If no voltage, defective or tripped engine circuit breaker 21 to 3 ........ If no voltage, defective main key switch 22 to 3 ........ If no voltage, defective engine start/stop switch, loose connection or bad wire. 22 to 3 ........ If no voltage, at terminal of alternator, defective resistor or wiring. If voltage is 12.5 volts or less at alternator (1to 3), repair or replace alternator. If voltage at battery is more than 16 Vdc, check for defective ground connection(s) between battery, frame, engine, and alternator before replacing alternator. BATTERIES Each battery should have about 12.6 Vdc with engine off. Lower readings than this is indicative of a weak battery and should be serviced.

300 Series & CR411 Electrical Troubleshooting

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Throttle & Fuel Grayhound 300 Series Analog Display Grayhound CR411

ENGINE RUNS AT IDLE BUT NOT FULL THROTTLE Main key switch ON, engine RUNNING, control circuit breaker SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. Throttle switch to FULL 48 to 3 ........ If no voltage, defective throttle switch. If voltage, defective throttle solenoid or open wiring in solenoid. ENGINE CRANKS BUT DOES NOT START Main key switch ON, brake switch to ENGAGE, hold permissive start switch closed, engine switch to RUN If no voltage: 1 to 3 .......... defective main key switch 20 to 3 ........ defective or tripped engine breaker 21 to 3 ........ defective main key switch 22 to 3 ........ defective engine start switch 23 to 3 ........ broken wire or defective permissive start switch or relay 23 to 3 ........ If voltage defective fuel solenoid ENGINE STOPS WHEN PERMISSIVE START SWITCH IS RELEASED Main key switch ON, brake switch ENGAGED, hold permissive start switch CLOSED After engine starts, the engine light should remain lit until the engine pressure rises above 5 psi and the engine temperature is below 223° F. Release permissive start switch after engine light goes out. 22 to 3 ........ If no voltage and engine dies, defective permissive start relay 300 Series & CR411 Electrical Troubleshooting

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Throttle & Fuel Grayhound 300 Series Analog Display Grayhound CR411 ENGINE LIGHT WILL NOT GO OUT AFTER ENGINE STARTS If continuity across engine water temperature switch, check for overheated engine or defective water temperature switch. If continuity across engine oil pressure switch, check for low engine oil pressure or defective engine oil pressure switch. ENGINE DOES NOT STOP Engine stop/start switch to STOP. 23 to 3 ........ If voltage, defective engine stop/start switch. If no voltage, defective fuel solenoid. ENGINE SHUTS OFF AFTER A PERIOD OF TIME Check the engine oil pressure and water temperature. One of these has exceeded limits and tripped the shutdown system.

300 Series & CR411 Electrical Troubleshooting

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Engine Start & Fuel - Elite Engine Grayhound CR300 Series Rubber Tire Pavers

Track Pavers

ENGINE CRANKS BUT DOES NOT START Main key switch ON, brake switch to ENGAGE, hold permissive start switch closed, engine switch to START If no voltage: 1 to 3 .......... defective main key switch 20 to 3 ........ defective or tripped engine breaker 21 to 3 ........ defective main key switch 22 to 3 ........ defective engine start switch 23A to 3 ..... defective K22 relay 23 to 3 ........ broken wire or defective permissive start switch or relay 23 to 3 ........ If voltage defective fuel solenoid Note: Pull-in coil (wire 23A) has 12VDC only while cranking engine

300 Series & CR411 Electrical Troubleshooting

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Horn Grayhound 300 Series Analog Display Grayhound CR411

Main Keyswitch 1

12 VDC 3

0 Horn

Power 1

100

19

3

18

3

30 A 100

Horn Relay

Horn Switch

HORN DOES NOT WORK Hold horn switch ON. 1 to 3 .......... If no voltage, defective main key switch. 100 to 3 ...... If no voltage, defective power circuit breaker. If voltage, check: 19 to 3 ........ If voltage, defective horn. If no voltage, check: 100 to 18 ..... If 12 Vdc, replace K3 relay If no voltage, check: 18 to 3 ........ If no voltage, defective K3 relay. If voltage, defective horn switch

300 Series & CR411 Electrical Troubleshooting

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Gauges Grayhound 300 Series Analog Display Grayhound CR411

NO GAUGES WORK 20 to 3 ........ If no voltage, check engine circuit breaker 21 to 3 ........ If no voltage, defective main key switch 22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring. INDIVIDUAL GAUGES DO NOT WORK Water temperature: 22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring. 7 to 3 .......... 1500 ohms at 100° F, 125 ohms at 210° F Oil pressure: 22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring. 8 to 3 .......... 0 to 80 ohms at 0 to 80 PSI. Hydraulic temperature: 22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring. 9 to 31 ........ 1500 ohms at 100° F, 125 ohms at 210° F Fuel level: 22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring. 10 to 3 ........ 0 to 90 ohms = empty to full Hourmeter/tachometer: (requires a functional alternator for proper operation) 22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring. 11 to 3 ........ If voltage at tachometer is approximately. 8 Vac with engine running, replace tachometer. 11 to 3 ........ If no voltage at tach., check at alternator, if no voltage, replace alternator. 300 Series & CR411 Electrical Troubleshooting

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Lights Grayhound 300 Series Analog Display Grayhound CR411

FLASHER LIGHTS/OPTIONAL STROBE DO NOT WORK Main key switch ON, flasher and engine circuit breaker SET, flasher switch ON engine switch to RUN position. If no voltage: 1 to 3 .......... defective main key switch 20 to 3 ........ defective engine breaker 21 to 3 ........ defective main key switch 22 to 3 ........ defective engine switch 113 to 3 ...... defective flasher switch 113A to 3 ... defective flasher circuit breaker If voltage 113 to 3 and if no voltage 114 to 3, defective flasher relay 111 to 3 ...... If no voltage, defective flasher. If voltage, check for bad light bulb 112 to 3 ...... If no voltage, defective flasher. If voltage, check for bad light bulb LIGHTS DO NOT WORK Main key switch ON, lights and engine circuit breaker SET, light switch ON, engine switch to RUN position. If no voltage: 1 to 3 .......... defective main key switch 20 to 3 ........ defective engine breaker 21 to 3 ........ defective main key switch 22 to 3 ........ defective engine switch 109 to 3 ...... defective light switch 109A to 3 ... defective light circuit breaker If voltage 109 to 3 and no voltage 110 to 3, defective lights relay 110 to 3 ...... If no voltage, defective light switch. If voltage, check for bad light bulb 300 Series & CR411 Electrical Troubleshooting

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Brakes Grayhound 300 Series Analog Display Grayhound CR411

1

1

Main Keyswitch

Control 46 15 A

0

12 VDC 3

Engage

Brake

34

34

Brake Release Sol.

3

'A' Release

BRAKES WILL NOT RELEASE If SWITCH is defective, the brakes WILL remain ENGAGED. Travel speed controllers, vibrators, automatic feed and screed control WILL NOT function. If SOLENOID is defective, the brakes WILL NOT RELEASE. Travel speed controllers, vibrators, automatic feed and screed control WILL function. Check brake solenoid DIN connector for light. If light is ON: (1) Check ground jumper pin 2 to GND pin on DIN connector for loose connection. (2) Defective solenoid coil or hydraulic problem If NO light: 34 to 3 ........ If no voltage is present, switch is defective. If voltage, defective solenoid or DIN connector.

300 Series & CR411 Electrical Troubleshooting

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Travel/Pave (P2) System Grayhound CR361 Analog Display

1

Main Keyswitch

12 VDC 3

0

Range 1

Control 46 15 A

P/2

42

42 Range Sol.

3

Travel Range 46 Range Switch Rubber Tire

P/4 P/2

27 42

Travel

RANGE SWITCH DOES NOT WORK If range switch does not function: Range switch in TRAVEL. Check travel range solenoid valve DIN connector for light. If light: (1) Check ground jumper pin 2 to GND pin on DIN connector for loose or bad connection. (2) Defective solenoid coil or auxiliary hydraulic problem. 42 to 3 ........ If no voltage is present, switch is defective. If voltage, defective solenoid or DIN connector.

300 Series & CR411 Electrical Troubleshooting

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Front Wheel Assist Grayhound CR351 Analog Display Grayhound CR411

1

Main Keyswitch

Control 1 46 15 A

12 VDC 3

0

Range

P/4 P/2

27 42

Fwd Sol. Range Sol.

3 3

Travel

RANGE SWITCH DOES NOT WORK IN TRAVEL Range switch in TRAVEL. Check range solenoid DIN connector for light. If light is ON: Check ground jumper pin 2 to GND pin for loose or bad connection. If connection is good, defective solenoid or hydraulic problem. If NO light: 42 to 3 ........ If no voltage is present, switch is defective. If voltage, defective solenoid or DIN connector. RANGE SWITCH DOES NOT WORK IN P4 (Front wheel assist only) Range switch to P4 (front wheel assist). Check front wheel assist solenoid DIN connector for light. If light is ON: Check ground jumper pin 2 to GND pin for loose or bad connection. If connection is good, defective solenoid or hydraulic problem. If NO light: 27 to 3 ........ If no voltage is present, switch is defective. If voltage, defective solenoid or DIN connector. If DIN connector light is on, defective solenoid.

300 Series & CR411 Electrical Troubleshooting

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Travel Control Grayhound CR351 Analog Display Grayhound CR411 Main Keyswitch 1

1

12 VDC 3

0 Control 46 15 A

46

Brake

Engage

34

'A' Release 4 Pin Packard

77 C B D

Travel

A

3 RH A B Reverse Coils 73 3 LH A B 3 3

34 73 3 74

74

Speed B

Controller

C A

CW

Max Paver Speed 1K½

3 LH D C Forward Coils 78 3 RH D C

3 Pin Packard

TRAVEL SPEED CONTROL DOES NOT WORK (Neither drive wheel moves) Main key switch ON, engine RUNNING, control circuit breaker SET, brakes RELEASED. Carefully actuate the manual override lever on each travel pump. If pumps operate using the manual override levers, proceed with checks. If pumps do not operate, refer to the Hydraulic Troubleshooting section. Without starting engine, main key switch ON, engine start/stop switch to RUN, control circuit breaker SET. 1 to 3 .......... If no voltage, defective Main Key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. Release BRAKES, set the max paver speed dial to MAX and travel lever fully FORWARD. 34 to 3 ........ If no voltage, defective brake switch. 74 to 3 ........ Voltage should be 1.6 Vdc. 78 to 3 ........ Voltage should be 1.6 Vdc. If no voltage, check the S1 limit switch on the travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If the voltage does not decrease to 0.15 Vdc, turn the main key switch off and remove wires 74 and 78 from the console terminal block. Check the resistance of the console cable wiring: 74 to 3 ........ Resistance should be 15 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins C and D on the pump. Resistance should be 15 to 25 ohms. 78 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. 300 Series & CR411 Electrical Troubleshooting

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Travel Control Grayhound CR351 Analog Display Grayhound CR411 Check resistance across pins D and C on the pump. Resistance should be 15 to 25 ohms. Release BRAKES, set the max paver speed dial to MAX and the travel lever fully REVERSE. 34 to 3 ........ If no voltage, defective brake switch. 73 to 3 ........ Voltage should be 1.6 Vdc. 77 to 3 ........ Voltage should be 1.6 Vdc. If no voltage, check the S1 limit switch on the travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If voltage does not decrease to 0.15 Vdc, turn the main key switch off and remove wires 73 and 77 from the console terminal block. Check the resistance of the console cable wiring: 73 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace EDCif open or shorted. 77 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace EDC if open or shorted CHECKING THE TRAVEL SPEED POT Disconnect the plug to the travel speed pot and check the resistance of the pot. A to B ........ 1000 ±100 ohms at all times A to C ........ Ohms should vary as dial is rotated. B to C ......... Ohms should vary as dial is rotated. PAVER PULLS TO ONE SIDE If paver turns severely to left: Operate manual override on left pump. If left pump operates proceed with electrical checks. If not, refer to hydraulic section. Electrical Checks: Check the resistance of the console cable wiring: 73 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace EDC if open or shorted. Check the resistance of the console cable wiring: 74 to 3 ........ Resistance should be 15 to 25 ohms.

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Travel Control Grayhound CR351 Analog Display Grayhound CR411 If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins C and D on the pump. Resistance should be 15 to 25 ohms. If paver turns severely to right: Operate manual override on right pump. If right pump operates, proceed with electrical checks. If not refer to hydraulic section. Electrical checks: 77 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace EDC if open or shorted. 78 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump.

300 Series & CR411 Electrical Troubleshooting

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Travel Control & Steer Assist Grayhound Rubber Tire Pavers 1999 & After w/46065-500-34 Module

300 Series & CR411 Electrical Troubleshooting

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Travel Control & Steer Assist Grayhound Rubber Tire Pavers 1999 & After w/46065-500-34 Module TRAVEL SPEED CONTROL DOES NOT WORK (Neither drive wheel moves) Main key switch ON, engine RUNNING, control circuit breaker SET, brakes RELEASED. Carefully actuate the manual override lever on each travel pump. If pumps operate using the manual override levers, proceed with checks. If pumps do not operate, refer to the Hydraulic Troubleshooting section. Without starting engine, main key switch ON, engine start/stop switch to RUN, control circuit breaker SET. 1 to 3 .......... If no voltage, defective Main Key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. Release BRAKES, set the max paver speed dial to MAX and travel lever fully FORWARD. 34 to 3 ........ If no voltage, defective brake switch. 74 to 3 ........ For 351, voltage should be 1.6 VDC. For 451/551, voltage should be 2.2 VDC. 78 to 3 ........ For 351, voltage should be 1.6 VDC. For 451/551, voltage should be 2.2 VDC. If no voltage, check the S1 limit switch on the travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If the voltage does not decrease to 0.15 Vdc, turn the main key switch off and remove wires 74 and 78 from the console terminal block. Check the resistance of the console cable wiring: 74 to 3 ........ Resistance should be 15 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins C and D on the pump. Resistance should be 15 to 25 ohms. 78 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins D and C on the pump. Resistance should be 15 to 25 ohms. Release BRAKES, set the max paver speed dial to MAX and the travel lever fully REVERSE. 34 to 3 ........ If no voltage, defective brake switch. 73 to 3 ........ For 351, voltage should be 1.6 VDC. For 451/551, voltage should be 2.2 VDC. 77 to 3 ........ For 351, voltage should be 1.6 VDC. For 451/551, voltage should be 2.2 VDC. If no voltage, check the S1 limit switch on the travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If voltage does not decrease to 0.15 Vdc, turn the main key switch off and remove wires 73 and 77 from the console terminal block. Check the resistance of the console cable wiring: 73 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace EDCif open or shorted. 300 Series & CR411 Electrical Troubleshooting

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Travel Control & Steer Assist Grayhound Rubber Tire Pavers 1999 & After w/46065-500-34 Module 77 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace EDC if open or shorted CHECKING THE TRAVEL SPEED POT Disconnect the plug to the travel speed pot and check the resistance of the pot. A to B ........ 1000 ±100 ohms at all times A to C ........ Ohms should vary as dial is rotated. B to C ......... Ohms should vary as dial is rotated. PAVER PULLS TO LEFT OR RIGHT • Move harness plug-in connector from ASSIST position to BYPASS position. This eliminates STEER ASSIST circuitry on Steer Assist Module. If this corrects problem, replace Steer Assist Module. If not, re-check wire connections between console and traction pumps as described above. STEER ASSIST DOES NOT WORK IN P/2 OR P/4 RANGE Steer assist is operational only in P/2 or P/4 Range. Proper operation is indicated when paver pivot turns in the direction that STEER ASSIST switch is held. DIFF. LOCK must also be functional. If DIFF. LOCK is not working, refer to that section first before proceeding. STEER ASSIST DOES NOT WORK IN LEFT POSITION • Range switch in P/2 or P/4 • STEER ASSIST switch held in Left direction • 79 to 3...........If no voltage, replace STEER ASSIST switch. If 12VDC: • 75 to 3...........If no voltage, replace STEER ASSIST switch. If 12VDC: • Check connections at Steer Assist Module, if OK replace Steer Assist Module. STEER ASSIST DOES NOT WORK IN RIGHT POSITION • Range switch in P/2 or P/4 • STEER ASSIST switch held in Right direction • 79 to 3 ..........If no voltage, replace STEER ASSIST switch. If 12VDC: • 76 to 3...........If no voltage, replace STEER ASSIST switch. If 12VDC: • Check connections at Steer Assist Module, if OK replace Steer Assist Module.

300 Series & CR411 Electrical Troubleshooting

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Travel Control Adjustment Procedure 3 Pot Controller Grayhound Tire Pavers

3 Pot Travel Controller

Low Threshold Reverse Maximum Pot Forward Maximum Pot

CONTROL HANDLE ADJUSTMENT PROCEDURE Initial Adjustment: (Electrical centering) Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running: 1. Turn both MAX adjustment pots on controller fully clockwise. 2. Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust Low Threshold Pot for 0.2 VDC from wire 74 to 3. 3. Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for 2.0 VDC from wire 74 to 3 4. Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0 VDC from wire 73 to 3

300 Series & CR411 Electrical Troubleshooting

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Travel Control Adjustment Procedure 3 Pot Controller Grayhound Tire Pavers

Operational Adjustment: Note: Center pumps prior to operational adjustments! Wheels off ground; Engine at Full Throttle; Brake switch RELEASED: 1. With Control Handle full forward and MAX PAVER SPEED dial at MIN; wheels should not turn. Adjust Low Threshold Pot so that wheels start to creep at dial setting of '1' to '1.5' but stop at MIN. 2. Turn MAX PAVER SPEED dial to MAX with Control Handle full forward: Check speed of wheel hubs with a tachometer and adjust Max Forward Pot until actual speed is at Maximum. If in doubt, turn pot CCW until speed decreases then back to max speed. 3. Put Control Handle full reverse: Check speed of wheel hubs with a tachometer and adjust Max Reverse Pot. until actual speed is at Maximum. If in doubt, turn pot CCW until speed decreases then back to max speed. 4. Repeat steps 1-3 until adjustment is not necessary. Bias Adjustment Wheels off ground; Engine at Full Throttle; Brake switch RELEASED, balance lines blocked: 1. Control Handle full forward, MAX PAVER SPEED dial at MIN; Slowly increase MAX PAVER SPEED dial until one or both wheels start to turn. 2. If one wheel is not turning carefully adjust neutral of non-turning side pump until both wheels are turning the same speed.

300 Series & CR411 Electrical Troubleshooting

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Travel Control Adjustment Procedure 3 Pot Controller Grayhound Track Pavers

3 Pot Travel Controller

Low Threshold Reverse Maximum Pot Forward Maximum Pot

LH CONTROL HANDLE ADJUSTMENT PROCEDURE Initial Adjustment: (Electrical centering) Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running: 1. Turn both MAX adjustment pots on controller fully clockwise. 2. Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust Low Threshold Pot for 0.2 VDC from wire 74 to 3. 3. Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for 2.0 VDC from wire 74 to 3 4. Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0 VDC from wire 73 to 3

300 Series & CR411 Electrical Troubleshooting

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Travel Control Adjustment Procedure 3 Pot Controller Grayhound Track Pavers

3 Pot Travel Controller

Low Threshold Reverse Maximum Pot Forward Maximum Pot

RH CONTROL HANDLE ADJUSTMENT PROCEDURE Initial Adjustment: (Electrical centering) Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running: 1. Turn both MAX adjustment pots on controller fully clockwise. 2. Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust Low Threshold Pot for 0.2 VDC from wire 77 to 3. 3. Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for 2.0 VDC from wire 77 to 3 4. Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0 VDC from wire 78 to 3

300 Series & CR411 Electrical Troubleshooting

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Travel Control Adjustment Procedure 3 Pot Controller Grayhound Track Pavers

Operational Adjustment: Note: Center pumps prior to operational adjustments! Engine at Full Throttle; Brake switch RELEASED, hydraulic fluid at operating temperature: 1. With Control Handle full forward and MAX PAVER SPEED dial at MIN; tracks should not move. 2. Adjust Low Threshold Pot so that both tracks start to creep at dial setting of '1' to '1.5' but stop at MIN. 3. Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full forward: Adjust each MAX Forward Pot so that track speeds match (Paver goes straight) and paver is at maximum attainable speed. If in doubt, turn pot CCW until speed decreases then back to max speed. 4. Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full reverse: Adjust each MAX Reverse Pot so that track speeds match (Paver goes straight) and paver is at maximum attainable speed. If in doubt, turn pot CCW until speed decreases then back to max speed. 5. Repeat steps 1-4 until adjustment is not necessary.

300 Series & CR411 Electrical Troubleshooting

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Travel Control Adjustment Procedure Grayhound Tire Pavers Analog Display w/Lever Control

MINIMUM Forward Pot

MINIMUM Reverse Pot

MAXIMUM Forward Pot

MAXIMUM Reverse Pot

CONTROL HANDLE ADJUSTMENT PROCEDURE Initial Adjustment: (Electrical centering) Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running: . Turn both MAX adjustment pots on controller fully clockwise. . Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust MIN Forward Pot for 0.2 VDC from wire 74 to 3. . Travel lever full REVERSE, MAX PAVER SPEED dial to MIN: Adjust MIN Reverse Pot Clockwise until voltage increases from wire 73 to 3 then turn back. Should be about 0.2 VDC . Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for 2.0 VDC from wire 74 to 3 . Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0 VDC from wire 73 to 3 . While measuring voltage from 73 to 3, turn MAX PAVER SPEED dial slowly down from MAX to MIN with handle in full reverse: Voltage should decrease smoothly down to about 0.2 VDC. If not repeat steps 1-5. . While measuring voltage from 74 to 3, turn MAX PAVER SPEED dial slowly down from MAX to MIN with handle in full forward: Voltage should decrease smoothly down to about 0.2 VDC. If not repeat steps 1-5.

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Travel Control Adjustment Procedure Grayhound Tire Pavers Analog Display w/Lever Control Operational Adjustment: Note: Center pumps prior to operational adjustments! Wheels off ground; Engine at Full Throttle; Brake switch RELEASED: . With Control Handle full forward and MAX PAVER SPEED dial at MIN; wheels should not turn. Adjust MIN Forward Pot so that wheels start to creep at dial setting of '1' to '1.5' but stop at MIN. . With Control Handle full reverse and MAX PAVER SPEED dial at MIN; wheels should not turn. Adjust MIN Reverse Pot so that wheels start to creep at dial setting of '1' to '1.5' but stop at MIN. . Turn MAX PAVER SPEED dial to MAX with Control Handle full forward: Check speed of wheel hubs with a tachometer and adjust Max Forward Pot until actual speed is at Maximum. If in doubt, turn pot CCW until speed decreases then back to max speed. . Put Control Handle full reverse: Check speed of wheel hubs with a tachometer and adjust Max Reverse Pot. until actual speed is at Maximum. If in doubt, turn pot CCW until speed decreases then back to max speed. . Repeat steps 1-5 until adjustment is not necessary. Bias Adjustment Wheels off ground; Engine at Full Throttle; Brake switch RELEASED, balance lines blocked: 1. Control Handle full forward, MAX PAVER SPEED dial at MIN; Slowly increase MAX PAVER SPEED dial until one or both wheels start to turn. 2. If one wheel is not turning carefully adjust neutral of non-turning side pump until both wheels are turning the same speed.

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A Terex Company

Differential Lock Grayhound CR351 Analog Display Grayhound CR411

DIFFERENTIAL LOCK DOES NOT WORK IN P/2 OR P/4 RANGE Differential Lock is operational only in P/2 or P/4 Range. Proper operation is indicated when steering becomes difficult to impossible other than in a straight line. To troubleshoot a suspected problem: • Range switch in P/2 or P/4 • DIFF. LOCK switch held in ON position Check Diff. Lock solenoid DIN connector for light • If light is ON, check for magnetic field with a small screwdriver at the solenoid coil. If no field, check ground jumper from pin 2 to GND pin in DIN connector for tightness. If connection is good, check coil resistance for about 6 ohms. Replace solenoid if bad. If there was a magnetic field, refer to Hydraulic Troubleshooting. • If no light check: • 46A to 3.........If no voltage, replace K20 relay. If 12 VDC, check: • 79 to 3............If no voltage, replace DIFF. LOCK switch. If 12 VDC • 79 to Ground at solenoid.....No voltage indicates defective wiring to solenoid. 12 VDC at the solenoid without a light indicates either a bad Ground or defective DIN connector. DIFFERENTIAL LOCK FUNCTIONS IN TRAVEL RANGE Differential Lock should NOT work in TRAVEL RANGE. If it is, check: • DIN connector for light. If ON check: • 46A to 3.........If no voltage, check wire 79 for cross short to 12 VDC If 12 VDC, check: • 42 to 3 at K20 relay.....If 12 VDC, unplug K20 relay. If Diff. Lock solenoid drops out, replace K20 relay. If no voltage, check for defective wiring in console. • If DIN light is OUT, refer to Hydraulic Troubleshooting.

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Steer Assist Grayhound CR351 Analog Display Grayhound CR411

STEER ASSIST DOES NOT WORK IN P/2 OR P/4 RANGE Steer assist is operational only in P/2 or P/4 Range. Proper operation is indicated when paver pivot turns in the direction that STEER ASSIST switch is held. DIFF. LOCK must also be functional. If DIFF. LOCK is not working, refer to that section first before proceeding. STEER ASSIST DOES NOT WORK IN LEFT POSITION • Range switch in P/2 or P/4 • STEER ASSIST switch held in Left direction • 79 to 3 with .If no voltage, replace STEER ASSIST switch. If 12VDC: • 75 to 3...........If no voltage, replace STEER ASSIST switch. If 12VDC: • Is KL relay pulling in? If not, replace or swap with KR relay to check. • If KL relay does pull in, check 74 to 3 in Forward or 73 to 3 in Reverse. Voltage should be 0. If not, replace or swap KL relay with KR relay to check. 300 Series & CR411 Electrical Troubleshooting

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Steer Assist Grayhound CR351 Analog Display Grayhound CR411 STEER ASSIST DOES NOT WORK IN RIGHT POSITION • Range switch in P/2 or P/4 • STEER ASSIST switch held in Right direction • 79 to 3 ..........If no voltage, replace STEER ASSIST switch. If 12VDC: • 76 to 3...........If no voltage, replace STEER ASSIST switch. If 12VDC: • Is KR relay pulling in? If not, replace or swap with KL relay to check. • If KR relay does pull in, check 78 to 3 in Forward or 77 to 3 in Reverse. Voltage should be 0. If not, replace or swap KR relay with KL relay to check. PAVER PULLS TO LEFT WITH STEER ASSIST IN RELEASED (OFF) POSITION • Range switch in P/2 or P/4 • STEER ASSIST switch released • 75 to 3 .........If 12VDC, replace STEER ASSIST switch. If no voltage check: • 74 to 3 in Forward, 73 to 3 in Reverse. If voltage is 0, replace or swap KL relay with KR relay to check. If voltage is identical to 78 to 3 in Forward or 77 to 3 in Reverse, refer to Hydraulic Troubleshooting. PAVER PULLS TO RIGHT WITH STEER ASSIST IN RELEASED (OFF) POSITION • Range switch in P/2 or P/4 • STEER ASSIST switch released • 76 to 3 .........If 12VDC, replace STEER ASSIST switch. If no voltage check: • 78 to 3 in Forward, 77 to 3 in Reverse. If voltage is 0, replace or swap KR relay with KL relay to check. If voltage is identical to 74 to 3 in Forward or 73 to 3 in Reverse, refer to Hydraulic Troubleshooting.

300 Series & CR411 Electrical Troubleshooting

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LH Travel Speed Control Grayhound CR361 Analog Display Main Keyswitch

1

1

Control 46

46

12 VDC 0

Brake

15 A

3 Engage

34

'A' Release 4 Pin Packard C A D

Left Travel Speed Controller

B B C A

3

Forward Coil 73 3 LH A B 3 3

74

74

34 73

CW

Max Paver Speed 1K

LH D C Reverse Coil

3

3 Pin Packard Dual Speed Pot

LH TRAVEL SPEED CONTROL DOES NOT WORK Main key switch ON, engine RUNNING, control circuit breaker SET, brakes RELEASED. Carefully actuate the manual override lever on each travel pump. If pumps operate using the manual override levers, proceed with checks. If pumps do not operate, refer to the Hydraulic Troubleshooting section. Without starting the engine, main key switch to ON, engine start/stop switch to RUN, control circuit breaker SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. Release BRAKES. Set the max paver speed dial to MAX and the LH travel lever fully FORWARD. 34 to 3 ........ If no voltage, defective brake switch. 73 to 3 ........ Voltage should be 1.6 Vdc. If no voltage, check the S1 limit switch on the LH travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If the voltage does not decrease to 0.15 Vdc, turn main key switch OFF and remove wire 73 from the console terminal block. Check the resistance of the console cable wiring: 73 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Release BRAKES. Set the max paver speed dial to MAX and the LH travel lever fully REVERSE. 300 Series & CR411 Electrical Troubleshooting

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LH Travel Speed Control Grayhound CR361 Analog Display 34 to 3 ........ If no voltage, defective brake switch. 74 to 3 ........ Voltage should be 1.6 Vdc. If no voltage, check the S1 limit switch on the LH travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If voltage does not decrease to 0.15 Vdc, turn main key switch OFF and remove wire 74 from the console terminal block. Check the resistance of the console cable wiring: 74 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins C and D on the pump. Resistance should be 15 to 25 ohms. CHECKING THE TRAVEL SPEED POT Disconnect the plug to the travel speed pot and check the resistance of the pot. A to B ........ 1000 ±100 ohms at all times A to C ........ Ohms should vary as dial is rotated. B to C ......... Ohms should vary as dial is rotated.

300 Series & CR411 Electrical Troubleshooting

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RH Travel Speed Control Grayhound CR361 Analog Display

RH TRAVEL SPEED CONTROL DOES NOT WORK Main key switch ON, engine RUNNING, control circuit breaker SET, brakes RELEASED. Carefully actuate the manual override lever on each travel pump. If pumps operate using the manual override levers, proceed with checks. If pumps do not operate, refer to the Hydraulic Troubleshooting section. Without starting engine, main key switch to ON, engine start/stop switch to RUN, control circuit breaker is SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. Release the BRAKES, max paver speed dial to MAX and the RH travel lever fully FORWARD. 34 to 3 ........ If no voltage, defective Brake switch. 77 to 3 ........ Voltage should be 1.6 Vdc. If no voltage, check the S1 limit switch on the RH travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If the voltage does not decrease to 0.15 Vdc, turn main key switch OFF and remove wire 77 from the console terminal block. Check the resistance of the console cable wiring: 77 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. 300 Series & CR411 Electrical Troubleshooting

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RH Travel Speed Control Grayhound CR361 Analog Display Release BRAKES, set max paver speed dial to MAX and the RH travel lever fully REVERSE. 34 to 3 ........ If no voltage, defective brake switch. 78 to 3 ........ Voltage should be 1.6 Vdc. If no voltage, check the S1 limit switch on the RH travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If voltage does not decrease to 0.15 Vdc, turn main key switch OFF and remove wire 78 from the console terminal block. Check the resistance of the console cable wiring: 78 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins C and D on the pump. Resistance should be 15 to 25 ohms. CHECKING THE TRAVEL SPEED POT Disconnect the plug to the travel speed pot and check the resistance of the pot. A to B ........ 1000 ±100 ohms at all times A to C ........ Ohms should vary as dial is rotated. B to C ......... Ohms should vary as dial is rotated.

300 Series & CR411 Electrical Troubleshooting

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Travel Control Adjustment Procedure Grayhound Track Pavers Analog Display w/Lever Controls

MINIMUM Forward Pot

MINIMUM Reverse Pot

MAXIMUM Forward Pot

MAXIMUM Reverse Pot

LH CONTROL HANDLE ADJUSTMENT PROCEDURE Initial Adjustment: (Electrical centering) Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running: . Turn both MAX adjustment pots on controller fully counterclockwise. . Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust MIN Forward Pot for 0.2 VDC from wire 73 to 3. . Travel lever full REVERSE, MAX PAVER SPEED dial to MIN: Adjust MIN Reverse Pot Clockwise until voltage increases from wire 74 to 3 then turn back. Should be about 0.2 VDC . Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for 2.0 VDC from wire 73 to 3 . Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0 VDC from wire 74 to 3 . While measuring voltage from 74 to 3, turn MAX PAVER SPEED dial slowly down from MAX to MIN with handle in full reverse: Voltage should decrease smoothly down to about 0.2 VDC If not repeat steps 1-5. . While measuring voltage from 73 to 3, turn MAX PAVER SPEED dial slowly down from MAX to MIN with handle in full forward: Voltage should decrease smoothly down to about 0.2 VDC If not repeat steps 1-5.

300 Series & CR411 Electrical Troubleshooting

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Travel Control Adjustment Procedure Grayhound Track Pavers Analog Display w/Lever Controls

MINIMUM Forward Pot

MINIMUM Reverse Pot

MAXIMUM Forward Pot

MAXIMUM Reverse Pot

RH CONTROL HANDLE ADJUSTMENT PROCEDURE Initial Adjustment: (Electrical centering) Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running: . Turn both MAX adjustment pots on controller fully counterclockwise. . Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust MIN Forward Pot for 0.2 VDC from wire 77 to 3. . Travel lever full REVERSE, MAX PAVER SPEED dial to MIN: Adjust MIN Reverse Pot Clockwise until voltage increases from wire 78 to 3 then turn back. Should be about 0.2 VDC . Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for 2.0 VDC from wire 77 to 3 . Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0 VDC from wire 78 to 3 . While measuring voltage from 78 to 3, turn MAX PAVER SPEED dial slowly down from MAX to MIN with handle in full reverse: Voltage should decrease smoothly down to about 0.2 VDC If not repeat steps 1-5. . While measuring voltage from 77 to 3, turn MAX PAVER SPEED dial slowly down from MAX to MIN with handle in full forward: Voltage should decrease smoothly down to about 0.2 VDC If not repeat steps 1-5.

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Travel Control Adjustment Procedure Grayhound Track Pavers Analog Display w/Lever Controls Operational Adjustment: Note: Center pumps prior to operational adjustments! Engine at Full Throttle; Brake switch RELEASED, hydraulic fluid at operating temperature: . With Control Handles full forward and MAX PAVER SPEED dial at MIN, tracks should not move. . Both tracks should start moving at the same speed with a dial setting of '1' to '1.5'. If not, adjust each MIN Forward Pot so that both tracks start to creep at dial setting of '1' to '1.5' but stop at MIN. . With Control Handle full reverse and MAX PAVER SPEED dial at MIN, tracks should not move. . Both tracks should start moving at the same speed with a dial setting of '1' to '1.5'. If not, adjust each MIN Reverse Pot so that both tracks start to creep at dial setting of '1' to '1.5' but stop at MIN. . Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full forward. . Adjust each MAX Forward Pot so that track speeds match (Paver goes straight) and paver is at maximum attainable speed. Maximum attainable speed is when turning the MAX Forward pot CW does not cause paver to turn but turning CCW will cause a turn. . Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full reverse. . Adjust each MAX Reverse Pot so that track speeds match (Paver goes straight) and paver is at maximum attainable speed. Maximum attainable speed is when turning the MAX Reverse pot CW does not cause paver to turn but turning CCW will cause a turn. . Repeat steps 1-8 until adjustment is not necessary.

300 Series & CR411 Electrical Troubleshooting

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Susmic 10 Dual Path Control Calibration Procedures Grayhound Track Pavers

Pavers 1999 & Before

Pavers 1999 & After

Scope This document covers the calibration procedures for asphalt pavers equipped with the Sauer-Sunstrand Susmic 10 dual path controller. When to Calibrate These procedures are to be performed after initial vehicle assembly and when a sensor, EDC, pump or motor is replaced. Before beginning these procedures, check to make sure that the Susmic 10 (S10) is properly wired and all inputs are as expected. Table 1 shows all controller inputs and loads and their expected ranges.

300 Series & CR411 Electrical Troubleshooting

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Susmic 10 Dual Path Control Calibration Procedures Grayhound Track Pavers Input Forward switch Reverse switch

Wire 351 35 2

Counter rotation

353

Calibrate Brake switch Steer sensor signal Speed pot signal Battery + Battery + Ignition

355 34 332 342 22 22 22

Output Steer sensor power Speed pot power Left forward EDC Left reverse EDC Right forward EDC Right reverse EDC

Wire 331 341 73 74 77 78

Pin Value P1-9 Zero volts in forward P1-27 Zero volts in reverse Zero volts in counter rotate P1-8 (pave mode only) P1-15 Zero volts when calibrate held P1-25 12 volts when brake is released P1-18 1 to 4 volts, left to right P1-19 0.5 to 4.5 volts, min. to max. P1-1 12 volts P1-10 12 volts P1-12 12 volts Pin Value P1-23 5 volts P1-24 5 volts P1-7 0 to 3 volts* P1-20 0 to 3 volts* P1-6 0 to 3 volts* P1-21 0 to 3 volts*

* Depends on Speed Pot Position All Voltage measured made with respect to ground. Ground @ pin P1-2, P1-3, P1-22, P1-13 and EDC Pins B & C. System Function Check A system function check should be performed whenever a component is changed and prior to calibration. Check that all components are installed and that wiring is attached properly. Make sure that all persons are clear of the machine and that space for machine movement exists to the front, rear and both sides. The engine should be at low idle setting and the machine in the work range of operation. 1) Center the steering wheel. Turn the speed set potentiometer to its MINIMUM position. Move the throttle switch to the IDLE position. Move the pave mode switch to the PAVE position. Move the Counter Rotate switch to the NORMAL position. Move the FNR switch to the neutral (N) position. 2) Start the vehicle. The tracks should not move. 3) Move the BRAKE switch to the RELEASE position. The tracks should not move. 4) Slowly turn the SPEED SET potentiometer clockwise. Neither track should move. 300 Series & CR411 Electrical Troubleshooting

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Susmic 10 Dual Path Control Calibration Procedures Grayhound Track Pavers 5) Turn the SPEED SET potentiometer to the MINIMUM position. Move the FNR switch to the forward (F) position. The tracks should not move. 6) Slowly turn the SPEED SET potentiometer clockwise. Both tracks should begin to move slowly forward (clockwise). As the SPEED SET pot is increased, the track speed should increase. 7) Slowly turn the STEERING WHEEL to the left. The left track should slow to stop as the wheel is turned. Slowly center the STEERING WHEEL. The left track should speed up to its original rate. 8) Slowly turn the STEERING WHEEL to the right. The right track should slow to stop as the wheel is turned. Slowly center the STEERING WHEEL. The right track should speed up to its original rate. 9) Move the FNR switch to the neutral (N) position. Both tracks should stop. 10) Move the FNR switch to the reverse (R) position. Both tracks should begin turning in reverse. 11) Slowly turn the STEERING WHEEL to the left. The left track should slow to stop as the wheel is turned. Slowly center the STEERING WHEEL. The left track should speed up to its original rate. 12) Slowly turn the STEERING WHEEL to the right. The right track should slow to stop as the wheel is turned. Slowly center the STEERING WHEEL. The right track should speed up to its original rate. 13) Slowly turn the SPEED SET potentiometer counterclockwise towards minimum. Both tracks should slow to a stop by the time the speed pot is at its minimum position. 14) Move the FNR switch to the neutral (N) position. Both tracks should be stopped. If the vehicle performs as described above, the system is prepared for calibration.

300 Series & CR411 Electrical Troubleshooting

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Susmic 10 Dual Path Control Calibration Procedures Grayhound Track Pavers CALIBRATION: Calibration procedures are to be performed after initial vehicle assembly and when a sensor, speed set dial, EDC, pump or motor is replaced. Before beginning these procedures, check to make sure that the controller is properly wired and that all test values are as expected. Before beginning calibration, move the vehicle to an open area with 30+ yard run-out. 1) ENGINE switch in STOP. PAVER SPEED dial at minimum. THROTTLE switch in IDLE. RANGE switch in PAVE. COUNTER ROTATE switch in NORMAL. FNR switch in neutral (N). STEERING WHEEL MUST BE CENTERED. 2) Hold the CAL-RUN switch in the CAL position while starting the vehicle. Do not release CAL switch until Engine is brought to FULL THROTTLE. 3) Move the BRAKE switch to the RELEASE position. 4) Turn the STEERING WHEEL all the way to the left and hold. 5) Move the FNR switch to the forward (F) position. Watch the left track closely. As soon as the track begins to move, flip the FNR switch back to neutral (N). 6) Move the FNR switch to the reverse (R) position. Watch the left track closely. As soon as the track begins to move, flip the FNR switch back to neutral (N). 7) Turn the STEERING WHEEL all the way to the right and hold. 8) Move the FNR switch to the forward (F) position. Watch the right track closely. As soon as the track begins to move, flip the FNR switch back to neutral (N). 9) Move the FNR switch to the reverse (R) position. Watch the right track closely. As soon as the track begins to move, flip the FNR switch back to neutral (N). 10) Center the STEERING WHEEL. 11) Move the FNR switch to the forward (F) position. 12) Slowly turn the PAVER SPEED dial to MAXIMUM. Slowly turn PAVER SPEED dial counterclockwise until the vehicle just starts to slow down. Make sure the paver will respond to slight movements of the STEERING WHEEL. Steer paver in a straight path. After 5 seconds without moving the STEERING WHEEL or PAVER SPEED dial, move the FNR switch to the neutral (N) position. 13) Turn the PAVER SPEED dial to MINIMUM. 14) Move the FNR switch to the reverse (R) position. 15) Slowly turn the PAVER SPEED dial to MAXIMUM. Slowly turn PAVER SPEED dial counterclockwise until the vehicle just starts to slow down. Make sure the paver will respond to slight movements of the STEERING WHEEL. Steer paver in a straight path. After 5 seconds without moving the STEERING WHEEL or PAVER SPEED dial, move the FNR switch to the neutral (N) position. 16) Turn the PAVER SPEED dial to MINIMUM. 17) Press and release the CAL-RUN. Move the THROTTLE switch to the IDLE position. Move the BRAKE switch to the ENGAGE position. 18) Wait 5 seconds. 19) Shut off the engine to store values. 300 Series & CR411 Electrical Troubleshooting

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Susmic 10 Dual Path Control Calibration Procedures Grayhound Track Pavers Error Checks There are four (4) indicator lights (LED's) located on the side of the track steer controller module located inside of the console; 2 green LED's, 1 yellow and 1 red. Their function is as follows: 1st Green

Power Input

OK if Lit

2nd Green Yellow

Power Output Kernal (Program)

OK if Lit Blinks if functional

Red

Error

Error if lit

On earlier controllers, the red error light would be either ON or OFF, indicating an error. As of software version S0029109 and later, an error code has been assigned to the red LED. The code is a series of short and long flashes consisting of 4 flashes per error with a pause between each error(s). A short flash indicates a "0" and a long flash represents a "1". The following table lists the error codes along with the error associated with it: Error Code 1000* 1100* 1010* 1110* 0100* 0010* 0110* 0001* 1001* 0101* 1101* 0011* 1011 0111 1111

Error Description Steering sensor input is higher than calibrated Steering sensor input is lower than calibrated Steering sensor calibrated too high Steering sensor calibrated too low Speed dial input is higher than calibrated Speed dial input is lower than calibrated Speed dial input is calibrated too high Speed dial input is calibrated too low LH FWD EDC calibration fault RH FWD EDC calibration fault LH REV EDC calibration fault RH REV EDC calibration fault Sensor power fault LH EDC fault RH EDC fault

*Attempt to clear errors by re-calibrating first per complete calibration procedure.

300 Series & CR411 Electrical Troubleshooting

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Hopper Grayhound 300 Series Analog Display Grayhound CR411

1

Main Keyswitch

0

CONTROL Hopper 46 Wings 1 15 A

12 VDC

3

Raise

65

Raise Sol.

3

Lower

66

Lower Sol.

3

HOPPER WINGS DO NOT RAISE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 65 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. HOPPER WINGS DO NOT LOWER Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 66 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 300 Series & CR411 Electrical Troubleshooting

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Truck Hitch (Optional) Grayhound 300 Series Analog Display Grayhound CR411 Main Keyswitch

1

Control 1

12 VDC

Optional 46 Truck Hitch

15 A

3

0

Engage

61

Engage Sol.

3

Release

62

Release Sol.

3

TRUCK HITCH DOES NOT ENGAGE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 61 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. TRUCK HITCH DOES NOT RELEASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 62 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 300 Series & CR411 Electrical Troubleshooting

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Frame Raise Grayhound CR351 Analog Display Grayhound CR411

Main Keyswitch

1

1

Control

0

Rear 46 Frame

15 A

12 VDC 3

Raise

70

Raise Sol.

3

Lower

71

Lower Sol.

3

REAR FRAME DOES NOT RAISE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 70 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. REAR FRAME DOES NOT LOWER Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 71 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 300 Series & CR411 Electrical Troubleshooting

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LH Flow Gate Grayhound 300 Series Analog Display Grayhound CR411 Main Keyswitch

1

1

1

12 VDC 3

0

Control 46 15 A Power

LH Gate

30 A

Raise

103

Lower

104

K16

K16

100 100

K15

K15

101 YEL

102 RED 102

K16

3 3

LH Gate Motor 3 3

101 K15

LH GATE DOES NOT GO UP LH gate switch to RAISE. Check for mechanical bind on motor. 100 to 3 ...... If no voltage, defective circuit breaker. 103 to 3 ...... If no voltage, defective LH gate switch or console cable. Relay K15 should pull in. If not, check for defective relay coil or faulty ground. 101 to 102 .. If no voltage, defective K15 contacts. 101 to 102 .. LH gate motor leads. If no voltage, there is a break in front harness. If voltage, check for open motor. Motor resistance should be 0.5 ohms. LH GATE DOES NOT GO DOWN LH gate switch to LOWER. Check for mechanical bind on motor. 100 to 3 ...... If no voltage, defective circuit breaker. 104 to 3 ...... If no voltage, defective LH gate switch or console cable. Relay K16 should pull in. If not, check for defective relay coil or faulty ground. 102 to 101 .. If no voltage, defective K16 contacts. 102 to 101 .. LH gate motor leads. If no voltage, there is a break in front harness. If voltage, check for open motor. Motor resistance should be 0.5 ohms.

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RH Flow Gate Grayhound 300 Series Analog Display Grayhound CR411 Main Keyswitch 1

12 VDC 3

0

Control 1

46

RH Gate

15A

Raise

107

Lower

108

Power 1

100

K18 K18

100 30A

K17

K17

105

YEL

106 RED 106

K18

3 3

RH Gate Motor 3 3

105 K17

RH GATE DOES NOT GO UP RH gate switch to RAISE. Check for mechanical bind on motor. 100 to 3 ...... If no voltage, defective circuit breaker. 107 to 3 ...... If no voltage, defective RH gate switch or console cable. Relay K17 should pull in. If not, check for defective relay coil or faulty ground. 105 to 106 .. If no voltage, defective K17 contacts. 105 to 106 .. RH gate motor leads: If no voltage, there is a break in front harness. If voltage, check for open motor. Motor resistance should be 0.5 ohms. RH GATE DOES NOT GO DOWN RH gate switch to LOWER. Check for mechanical binds on motor. 100 to 3 ...... If no voltage, defective circuit breaker. 108 to 3 ...... If no voltage, defective RH gate switch or console cable. Relay K18 should pull in. If not, check for defective relay coil or faulty ground. 106 to 105 .. If no voltage, defective K18 contacts. 106 to 105 .. RH gate motor leads. If no voltage, there is a break in front harness. If voltage, check for open motor. Motor resistance should be 0.5 ohms.

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Material Flow Indicators Grayhound Pavers 1999 & Before

Material flow is sensed by switches mounted on the bottom edge of each flow gate. The switches can be manually actuated for testing purposes. Main key switch ON, control circuit breakers SET. LIGHT AND HORN DO NOT ACTIVATE WHEN MATERIAL IS NOT PRESENT Flow switch in down position (not contacting material) Left Side 88 to 3 ........ If no voltage, defective flow switch 88 to 3 ........ If voltage, defective light bulb 89 to 3 ........ If no voltage, defective diode or loose wire 89A to 3 ..... If no voltage, defective alarm silence relay 89A to 3 ..... If voltage, defective audible alarm Right Side 98 to 3 ........ If no voltage, defective flow switch 98 to 3 ........ If voltage, defective light bulb 89 to 3 ........ If no voltage, defective diode or loose wire 89A to 3 ..... If no voltage, defective alarm silence relay 89A to 3 ..... If voltage, defective audible alarm

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Material Flow Indicators Grayhound Pavers 1999 & Before ALARM CANNOT BE SILENCED 89 to 3 ........ (at switch) If no voltage, loose wire Push alarm silence switch 89B to 3 ..... If no voltage, defective alarm silence switch 89B to 3 ..... If voltage, defective alarm silence relay ALARM CAN ONLY BE SILENCED WHILE SWITCH IS HELD CLOSED Release alarm silence switch If alarm continues to sound, defective alarm silence relay or loose wire LIGHT AND HORN ACTIVATE WHEN MATERIAL IS PRESENT The flow switch mounted on the flow gate may stick in the closed position if not cleaned properly as part of daily cleaning procedure. Make sure flow switch is free to move.

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Material Flow Indicators Grayhound Pavers 1999 & After

Material flow is sensed by switches mounted on the bottom edge of each flow gate. The switches can be manually actuated for testing purposes. Alarm will not sound unless: At least 1 No Flow Light is ON, Screed in LOWER, Paver moving FORWARD, and Alarm Switch is ON. LIGHT AND HORN DO NOT ACTIVATE WHEN MATERIAL IS NOT PRESENT Flow switch in down position (not contacting material), Brake RELEASED, Travel in FORWARD, Screed Lift in LOWER, and Alarm Switch ON. Left Side 88 to 3 ........ If no voltage, defective flow switch 88 to 3 ........ If voltage, defective light bulb 89 to 3 ........ If no voltage, defective diode or loose wire 89C to 3 ..... If no voltage, defective screed lift switch 89B to 3 ..... If no voltage, defective alarm switch 89A to 3 ..... If no voltage, defective CRFA relay 89A to 3 ..... If voltage, defective alarm Right Side 98 to 3 ........ If no voltage, defective flow switch 98 to 3 ........ If voltage, defective light bulb 89 to 3 ........ If no voltage, defective diode or loose wire 89C to 3 ..... If no voltage, defective screed lift switch 89B to 3 ..... If no voltage, defective alarm switch 89A to 3 ..... If no voltage, defective CRFA relay 89A to 3 ..... If voltage, defective alarm 300 Series & CR411 Electrical Troubleshooting

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Material Flow Indicators Grayhound Pavers 1999 & After LIGHT AND HORN ACTIVATE WHEN MATERIAL IS PRESENT The flow switch mounted on the flow gate may stick in the closed position if not cleaned properly as part of daily cleaning procedure. Make sure flow switch is free to move.

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Screed Lift Grayhound 300 Series Analog Display Grayhound CR411

Main Keyswitch

1

Control 1 46

0

Screed Lift

15 A

12 VDC

Raise

3

63

Raise Sol.

3

64

Lower Sol.

3

Lower

SCREED DOES NOT RAISE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 63 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. SCREED DOES NOT LOWER Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 64 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 300 Series & CR411 Electrical Troubleshooting

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Screed Assist Grayhound 300 Series Analog Display Grayhound CR411

SCREED ASSIST WILL NOT COME ON Screed lift switch to LOWER, screed assist switch ON. 46 to 3 ........ If no voltage, defective engine stop/start switch. 64 to 3 ........ If no voltage, defective screed lift switch. 33 to 3 ........ If no voltage, defective screed assist switch. If voltage, check ground wire from solenoid to ground for bad connection. Check for magnetic field with small screwdriver at top of solenoid coil. If no magnetic field, defective screed assist solenoid. If system checks OK using above checks but system is not controlling screed properly, refer to hydraulic troubleshooting or adjustment procedures.

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Power Main Crown Grayhound 300 Series Analog Display Grayhound CR411

1

Main Keyswitch

Control 46 1 15 A

12 VDC

3

0

Main Crown

Increase

189

Increase Sol.

3

Decrease

190

Decrease Sol.

3

CROWN DOES NOT INCREASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 189 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. CROWN DOES NOT DECREASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 190 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 300 Series & CR411 Electrical Troubleshooting

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Vibrators Grayhound 300 Series Analog Display Grayhound CR411 Main Keyswitch 1

12 VDC 3

0

Note: Closed in forward (Travel Control) Control 46

1 15 A

Brake

Engage 34 Release

Vibrators Off

47 Forward L.S.

50

Vibrator Sol.

3

On

VIBRATORS WILL NOT COME ON Vibrator switch ON, brakes RELEASED, travel lever(s) FORWARD. Check DIN connector for light. If light is ON: Check pin 2 to GND pin on DIN connector for loose or bad connection. If NO light: 34 to 3 ........ If no voltage, defective brake switch. 47 to 3 ........ If no voltage, defective limit switch(es) on control handle(s). 50 to 3 ........ If no voltage, defective vibrator switch. If voltage but no light, check ground jumper pin 2 to GND pin for loose or bad connection. If good connection, check solenoid coil resistance. It should be approximately 6 ohms. VIBRATORS WILL NOT STOP Vibrator switch OFF. 50 to 3 ....... If voltage present, defective vibrator switch. If no voltage, defective vibrator solenoid valve.

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LH Hydraulic Strike-Off Extend All Grayhound Pavers

Retract Extend

CYLINDER DOES NOT EXTEND Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 174 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. CYLINDER DOES NOT RETRACT Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 173 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 300 Series & CR411 Electrical Troubleshooting

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RH Hydraulic Strike-Off Extend All Grayhound Pavers

Retract

Extend

CYLINDER DOES NOT EXTEND Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 184 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. CYLINDER DOES NOT RETRACT Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 183 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 300 Series & CR411 Electrical Troubleshooting

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LH Hydraulic Strike-Off Slope All Grayhound Pavers

SLOPE DOES NOT INCREASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 171 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. SLOPE DOES NOT DECREASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 172 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 300 Series & CR411 Electrical Troubleshooting

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RH Hydraulic Strike-Off Slope All Grayhound Pavers

SLOPE DOES NOT INCREASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 181 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. SLOPE DOES NOT DECREASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 182 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 300 Series & CR411 Electrical Troubleshooting

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LH Match Height All Grayhound Pavers

MATCH HEIGHT DOES NOT RAISE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 175 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. MATCH HEIGHT DOES NOT LOWER Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 176 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 300 Series & CR411 Electrical Troubleshooting

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RH Match Height All Grayhound Pavers

MATCH HEIGHT DOES NOT RAISE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 185 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. MATCH HEIGHT DOES NOT LOWER Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 186 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 300 Series & CR411 Electrical Troubleshooting

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A Terex Company

LH Main Burner #1 Grayhound 300 Series Analog Display Grayhound CR411 Main Keyswitch 1

12 VDC 0

3

Fastach Screed Burner Control Burner 1

115 60A 115

Fuel Pump Off On Fan No.1 Off

117

117

LH Main Burner (No.1) 116

116

118

Glow Plug No.1 118

On 115

Fuel Pump Motor 3 Fan Motor No.1

Glow Plug No.1

3

3

NO BURNERS LIGHT If fans work but no burners light, the problem is in the fuel delivery. If fuel pump is running, the problem is in the fuel line. If unsure if fuel pump is running, check the following: Main key switch ON, burner circuit breaker SET, burner fuel valve ON, fuel pump switch ON. 115 to 3 ...... If no voltage, defective burner circuit breaker 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage, check for open motor. If motor is operative, refer to screed system section of instructions to check fuel line. LEFT BURNER DOES NOT LIGHT Main key switch ON, burner circuit breaker SET, burner fuel valve ON, correct glow plug button DEPRESSED. 115 to 3 ...... If no voltage, defective circuit breaker. 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage present but no fuel to burner nozzle, defective fuel pump motor. 118 to 3 ...... If no voltage, defective glow plug push button or cable to glow plug. If voltage, but glow plug does not warm, defective glow plug or poor glow plug ground. LEFT BURNER FAN DOES NOT OPERATE 116 to 3 ...... If no voltage, defective fan switch. If voltage, defective fan motor.

300 Series & CR411 Electrical Troubleshooting

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RH Main Burner #2 Grayhound 300 Series Analog Display Grayhound CR411 Main Keyswitch 1

12 VDC 0

Burner 1

115 60A 115

3

Fuel Pump Off On Fan No.2 Off

Fastach Screed Burner Control

RH Main Burner (No.2) 126

126

128

Glow Plug No.2 128

On 115

117

117

Fuel Pump Motor 3 Fan Motor No.2

Glow Plug No.2

3

3

NO BURNERS LIGHT If fans work but no burners light, the problem is in the fuel delivery. If fuel pump is running, the problem is in the fuel line. If unsure if fuel pump is running, check the following: Main key switch ON, burner circuit breaker SET, burner fuel valve ON, fuel pump switch ON. 115 to 3 ...... If no voltage, defective burner circuit breaker. 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage, check for open motor. If motor is operative, refer to screed system section of instructions to check fuel line. RIGHT BURNER DOES NOT LIGHT Main key switch ON, burner circuit breaker SET, burner fuel valve ON, correct glow plug button DEPRESSED. 115 to 3 ...... If no voltage, defective circuit breaker. 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage present but no fuel to burner nozzle, defective fuel pump motor. 128 to 3 ...... If no voltage, defective glow plug push button or cable to glow plug. If voltage, but glow plug does not warm, defective glow plug or poor glow plug ground. RIGHT BURNER FAN DOES NOT OPERATE. 126 to 3 ...... If no voltage, defective fan switch. If voltage, defective fan motor.

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LH Ext. Burner #3 Grayhound 300 Series Analog Display Grayhound CR411 Main Keyswitch 1

12 VDC 0

3

Fastach Screed Burner Control Burner 1

115 60A 115

Fuel Pump Off On Fan No.3 Off

Lt. Ext. Burner (No.3) 136

136

138

Glow Plug No.3 138

On 115

117

117

Fuel Pump Motor 3 Fan Motor No.3

Glow Plug No.3

3

3

NO BURNER LIGHT If fans work but no burners light, the problem is in the fuel delivery. If fuel pump is running, the problem is in the fuel line. If unsure if fuel pump is running, check the following: Main key switch ON, burner circuit breaker SET, burner fuel valve ON, fuel pump switch ON. 115 to 3 ..... If no voltage, defective burner circuit breaker 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage, check for open motor. If motor is operative, refer to screed system section of instructions to check fuel line. LEFT BURNER DOES NOT LIGHT Main key switch ON, burner circuit breaker SET, burner fuel valve ON, correct glow plug button DEPRESSED. 115 to 3 ...... If no voltage, defective circuit breaker. 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage present but on fuel to burner nozzle, defective fuel pump motor. 138 to 3 ...... If no voltage, defective glow plug push button or cable to glow plug. If voltage, but glow plug does not warm, defective glow plug or poor glow plug ground. LEFT BURNER FAN DOES NOT OPERATE. 136 to 3 ...... If no voltage, defective fan switch. If voltage, defective fan motor.

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RH Ext. Burner #4 Grayhound 300 Series Analog Display Grayhound CR411 Main Keyswitch 1

12 VDC 0

Burner 1

115 60A 115

3

Fuel Pump Off On Fan No.4 Off

Fastach Screed Burner Control

RH Ext. Burner (No.4) 146

146

148

Glow Plug No.4 148

On 115

117

117

Fuel Pump Motor 3 Fan Motor No.4

Glow Plug No.4

3

3

NO BURNER LIGHT If fans work but no burners light, the problem is in the fuel delivery. If fuel pump is running, the problem is in the fuel line. If unsure if fuel pump is running, check the following: Main key switch ON, burner circuit breaker SET, burner fuel valve ON, fuel pump switch ON. 115 to 3 ..... If no voltage, defective burner circuit breaker 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage, check for open motor. If motor is operative, refer to screed system section of instructions to check fuel line. RIGHT BURNER DOES NOT LIGHT Main key switch ON, burner circuit breaker SET, burner fuel valve ON, correct glow plug button DEPRESSED. 115 to 3 ...... If no voltage, defective circuit breaker. 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage present but on fuel to burner nozzle, defective fuel pump motor. 148 to 3 ...... If no voltage, defective glow plug push button or cable to glow plug. If voltage, but glow plug does not warm, defective glow plug or poor glow plug ground. RIGHT BURNER FAN DOES NOT OPERATE. 146 to 3 ...... If no voltage, defective fan switch. If voltage, defective fan motor.

300 Series & CR411 Electrical Troubleshooting

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Rear Frame Compensator Adjustment All Grayhound Pavers

1) Raise or lower frame to about mid range. 2) While holding Comp Switch, adjust pot of Frame Oscillator Module for no net Raise or Lower. • Clockwise rotation on pot will cause frame to raise. • Counter-clockwise rotation on pot will cause frame to lower. • Adjustment must be done between full up and full down on the frame. 3) If properly adjusted, the frame will raise slightly immediate after Comp switch is actuated then stabilize at a "fixed" position.

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Remote Oil Cooler Motors Grayhound CR300 Series Pavers

COOLER FAN MOTORS ARE TO RUN WHEN ENGINE IS RUNNING

Wires

Voltage

23...3

12VDC

30...3

12VDC

31...3

12VDC

300 Series & CR411 Electrical Troubleshooting

Function

Comment

Cooler Relay Coil Voltage Readings with: Engine Running or... Cooler Main Switch in RUN position and Breaker Permissive Start Switch held ON Cooler Relay

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PAVER TECHNICAL MANUAL

300 Series & 411 Hydraulic Section

Technical Manual A Terex Company

Table of Contents Grayhound 300 Series/CR411 Cedarapids Lubricants ........................................................................................................ 1 Pressure Test Kit ................................................................................................................. 2 Component Location Map ............................................................................................. 3 - 4 Throttle ............................................................................................................................... 5 Brake System ...................................................................................................................... 6 Steering .......................................................................................................................... 7 - 8 Truck Hitch (Optional) ................................................................................................ 9 - 10 Hopper Wings ............................................................................................................ 11 - 12 Track Tension - Steel Track Pavers ........................................................................... 13 - 15 Rubber Track Hydraulic System ............................................................................... 17 - 21 Frame Raise CR351/CR411 Pavers ........................................................................... 22 - 23 Frame Raise CR361 Pavers ....................................................................................... 24 - 25 Screed Lift ................................................................................................................. 26 - 27 Screed Assist ............................................................................................................. 28 - 29 Tow Point .................................................................................................................. 30 - 31 Main Screed Power Crown ........................................................................................ 32 - 33 Screed Extend: 8 - 14 Screed ........................................................................................... 34 Screed Extend: Fastach 8' Screed .................................................................................... 35 Vibrator: Fastach 8' Screed .............................................................................................. 36 Vibrator: Fastach 10' Screed ............................................................................................ 37 Vibrators: 8 - 14 Screed ................................................................................................... 38 Conveyor - Grayhound 300 Series ................................................................................... 39 Conveyor - CR411 ............................................................................................................ 41 Traction System/Differential Lock - Grayhound 300 Series ..................................... 42 - 43 Traction System - CR411 ................................................................................................. 44 Front Wheel Assist (Optional) .......................................................................................... 45

300 Series & CR411 Hydraulic Troubleshooting

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300 Series & CR411 Hydraulic Troubleshooting

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300 Series & CR411 Hydraulic Troubleshooting

1

Greases

Hydraulic Oils

EP Gear Oils

Non-EP Gear Oils

Starfak 2201

Starfak 2202

Multifak EP 2

Starfak 00

Multifak HD 00

Multifak EP 1

Pinnacle 68

Rando HD 68

Pinnacle 32

Rando HD 32

Pinnacle 46

Pinnacle EP 320

Meropa 320

Rando HD 46

Pinnacle EP 220

N/A

Meropa 100

Meropa 220

N/A

Meropa 68

Pinnacle EP 150

Pinnacle 220

Regal R&O 220

Meropa 150

Pinnacle 150

Regal R&O 150

Pinnacle 68

Regal R&O 68

Pinnacle 100

Pinnacle 46

Regal R&O 46

Regal R&O 100

Synthetic

Mineral

Texaco

Alvania EP 2

Alvania EP 1

Synthetic

Albida SLC 220

N/A

Retinax TL 00

Tellus HD 68

Tellus HD 46

Tellus HD 32

Omala HD 320

Omala HD 220

N/A

N/A

N/A

Omala RL 220

Omala RL 150

Omala RL 100

Omala RL 68

Omala RL 46

Shell

Alvania EP 00

Tellus 68

Tellus 46

Tellus 32

Omala 320

Omala 220

Omala 150

Omala 100

Omala 68

Molina 220

Molina 150

Molina 100

Turbo T 068

Turbo T 046

Mineral

Mobilux EP 2

Mobilux EP 1

Mobilux EP 023

DTE 26

DTE 25

DTE 24

Mobilgear 632

Mobilgear 630

Mobilgear 629

Mobilgear 627

Mobilgear 626

Spartan EP 320

Mobilgear SHC 320

Mobilith SHC 220

N/A

Mobilith SHC 007

SHC 526

SHC 525

Lidok EP 2

Lidok EP 1

Lidok EP 000

Nuto H 68

Nuto H 46

Nuto H 32

Spartan EP 220

Mobilgear SHC 220

SHC 524

Spartan EP 150

Spartan EP 100

Spartan EP 68

Teresstic 220

Teresstic 150

Teresstic 100

Teresstic 68

Dura-Lith EP 2

Dura-Lith EP 1

Ulti-Plex Synthetic EP 1.5

Ulti-Plex Synthetic EP 1.5

N/ A

Rykon Premium Oil 68*

Rykon Premium Oil 46*

Rykon Premium Oil 32*

Tegra Synthetic Gear EP 320

Tegra Synthetic Gear EP 220

Tegra Synthetic Gear EP 150

*A refined mineral oil with properties between mineral and synthetic

Unirex SHP 220

Unirex SHP 460

Dura-Lith EP 00

Hydraulic Oil AW 68

Teresstic SHP 68 Unirex SHP 00

Hydraulic Oil AW 46

Hydraulic Oil AW 32

Teresstic SHP 32 Teresstic SHP 46

Gear Compound EP 320

Gear Compound EP 220 Spartan Synthetic EP 320

Spartan Synthetic EP 220

Gear Compound EP 150

Gear Compound EP 100

Spartan Synthetic EP 100 Spartan Synthetic EP 150

N/A

Gear Compound EP 68 N/A

N/A

N/A

Industrial Oil 220

Teresstic SHP 220

N/A

N/A

N/A

Industrial Oil 150

Industrial Oil 100

Industrial Oil 68

N/A

Teresstic SHP 150

Teresstic SHP 100

Teresstic SHP 68

Industrial Oil 46

Teresstic SHP 46

Synthetic

Chevron Mineral

Synthetic

Exxon Teresstic 46

Mineral

Mobilgear SHC 150

N/A

N/A

SHC 630

SHC 629

DTE Oil Extra Heavy DTE Oil BB

SHC 627

DTE Oil Heavy

SHC 626

DTE Oil Heavy Medium

Synthetic N/A

Mobil DTE Oil Medium

Mineral

List of mineral/synthetic interchanges for industrial lubricants used on Cedarapids equipment.

Technical Manual

A Terex Company

Cedarapids Lubricants

22479 (11/00)

Technical Manual

A Terex Company

Pressure Test Kit All Grayhound Pavers

45865-001-41 45865-002-27 45865-002-33

Gauge Gauge Guage

0-6000-PSI 0-100 PSI 0-600 PSI

45080-527-05

Adapter Gauge

Not Illustrated 7430-416 7430-344 7430-345 45080-527-14

45080-527-07 45080-527-15

Hose 36" Hose 10'

45080-527-17 45080-527-18 45080-527-16

45080-527-031 45080-527-061 45080-527-04

300 Series & CR411 Hydraulic Troubleshooting

Fitting Tee Tee Test Hose Union

#4 FS JIC Test Port #6 FS JIC Test Port #8 FS JIC Test Port

8" NPT Test Port 4" NPT Test Port #4 SAE Test Port

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Component Location Map Front Bulkhead

L35

L37 L36

L39

L38

L40

L41

L35 ................ L36 ................ L37 ................ L38 ................ L39 ................ L40 ................ L41 ................

300 Series & CR411 Hydraulic Troubleshooting

Front wheel assis solenoid valve LH pull point solenoid valve Truck hitch solenoid valve LH front wheel assist 5 way valve Hopper soleonid valve RH pull point solenoid vavle RH front wheel assist 5 way valve

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Component Location Map Rear Bulkhead

L30

L27

L31

L27 ................ Vibrator solenoid valve L30 ................ Screed lift solenoid valve L31 ................ Frame raise solenoid valve

300 Series & CR411 Hydraulic Troubleshooting

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Throttle Grayhound 300 Series/CR411 THROTTLE CYLINDER

FULL

IDLE

SOLENOID VAVLE

LH CONVEOYR CHARGE PUMP

RETURN

SUCTION

.85 CID

200 MESH STRAINER

HYDRAULIC TANK

ENGINE WILL NOT COME TO FULL THROTTLE Engine running Throttle switch to FULL THROTTLE. Check left conveyor to see if it operates. If it does not, refer to conveyor troubleshooting. Watch throttle cylinder. If it extends, refer to engine troubleshooting. Place a small screw driver next to the throttle solenoid. If no magnetic field is felt, refer to electrical. If a magnetic field is felt, throttle switch to IDLE. Remove hose from the rod end of the throttle cylinder. Throttle switch to FULL If oil comes out of the rod end port, blown packing. If no oil comes out rod end port, check flow restrictor for being plugged. If flow restrictor is not plugged, defective solenoid. ENGINE GOES TO FULL THROTTLE WITH SWITCH IN IDLE POSITION Refer to electrical troubleshooting. Check RH conveyor charge pressure. If no pressure refer to conveyor troubleshooting. (Charge pressure is required to hold throttle cylinder in Idle position.) 300 Series & CR411 Hydraulic Troubleshooting

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Technical Manual

A Terex Company

Brake System All Grayhound Pavers TO TRACTION PUMP

TORQUE HUB

Note: Charge Pressure suppled to traction pump and conveyor pumps from a common charge pump.

BRAKE ASSEMBLY TO TRACTION PUMP HYDRAULIC MOTOR

COOLER

CHARGE PRESSURE

TANK RANGE & BRAKE LINE TO OTHER TORQUE HUB

BRAKE SYSTEM The brakes are SPRING APPLIED and HYDRAULIC RELEASED. Pressure is supplied by the charge pump of the LH trandem pump. A brake solenoid valve when energized allows pressure to be applied to the brake piston, allowing the brakes to release. BRAKES WILL NOT RELEASE Engine at FULL THROTTLE. Brake switch to RELEASE. Travel speed dial set above (2). Travel engage/disengage switch to ENGAGE. (500 series only) Check brake solenoid DIN connector for light. If NO light refer to electrical troubleshooting. If light is ON. (1)Refer to electrical for checking ground connection. (2)Install a 600 psi gauge on RH conveyor or traction charge pump (depending on model) high pressure test port. (Do not engage conveyor or traction.) Pressure should be 218 to 265 psi for the brakes to release. If low refer to conveyor or traction system. (3)Install a 600 psi gauge between brake solenoid and brake hose. If no pressure or low, check flow orifice for obstruction or defective solenoid valve. (4)If correct pressure, check brake assembly for warped disks. EMERGENCY BRAKE RELEASE If machine has to be moved and the brakes are locked, refer to instruction decal located on the tool box lid of the paver. 300 Series & CR411 Hydraulic Troubleshooting

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Technical Manual

A Terex Company

Steering Grayhound Rubber Tire Pavers TEST PORT

Series: 300 *Full Load (RPM): 2100 *Max Flow (GPM): 8.4-11.0 Pressure (PSI): 2500 *Varies depending on vintage.

CASE DRAIN

SUCTION

PRESSURE

PRESSURE FILTER

200 MESH STRAINER RETURN HYDRAULIC TANK

AUXILIARY SYSTEM Check hydraulic fluid level. Engine at FULL THROTTLE. Check other auxiliary functions for operation (screed raise/lower, any extend/ retract function, pull point functions, etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. STEERING WILL NOT TURN LEFT OR RIGHT Engine at FULL THROTTLE. Remove the hose going to the left steering cylinder base end. Install a 3000 psi gauge on the end of the hose. Turn steering wheel to the left, pressure reading should be system pressure. If low or no pressure, defective steering valve. Remove the hose going to the right steering cylinder base end. Install a 3000 psi gauge on the end of the hose. Turn steering wheel to the right, pressure reading should be system pressure. If low or no pressure, defective steering valve. If problem occurs only after cylinders have been fully extended or retracted, check rephase ports Check ball not seating.

300 Series & CR411 Hydraulic Troubleshooting

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Steering Grayhound Rubber Tire Pavers STEERING WHEELS DRIFT APART It is normal for the wheel to drift apart over a period of time. To get them back in unison, steer against limits in either direction. If the wheels drift apart quickly, preform checks listed above. The cause is usually leaking piston packing on one or both steering cylinders. STEERING CYLINDER TEST With the steering cylinders at mid stroke, remove the rod end hoses. Cap the rod end ports of the cylinders and plug the hoses. Turn the steering wheel to the left. If the right steering cylinder rod starts to move outward the the packing of the right cylinder may be bad and need to be replaced, or the inner wall of the cylinder tube has a scratch or gouge in it, allowing the hydraulic fluid to go around the packing. Remove the cylinder and replace it. Turn the steering wheel to the right. If the left steering cylinder rod starts to move outward then the packing of the left cylinder may be bad and need to be replaced, or the inner wall of the cylinder tube has a scratch or gouge in it, allowing the hydraulic fluid to go around the packing. Remove the cylinder and replace it. Always remember to flush the hydraulic steering circuit before replacing the hoses onto the cylinders. This is done by coupling the hoses of each cylinder together and turning the steering wheel in one direction for several rotations and then in the other direction for several rotations.

300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Truck Hitch (Optional) All Grayhound Pavers Truck Hitch (Optional)

<<< Pressure <<<

Pressure Filter

Pressure Reducing Valve 900 PSI

2050 RPM

.913 CID

Solenoid Valve

200 Mesh Strainer

<<< Case Drain <<<

<<< Return <<<

Series: 300 *Full Load (RPM): 2100 *Max Flow (GPM): 8.4-11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

Manifold LH Front

Auxiliary Pump

Test Port

Test Port

2500 PSI

Holding Valve

AUXILIARY SYSTEM Check hydraulic fluid level. Engine at FULL THROTTLE. Hydraulic Tank Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, pull point functions and etc.) If other functions work, this indicates the problem in only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to ensure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. TRUCK HITCH WILL NOT EXTEND Engine at FULL THROTTLE. Manual needle valve open (this controls cylinder speed an needs to be open to some extent) Truck hitch switch to the EXTEND position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If truck hitch cylinder extends, defective solenoid. If truck hitch cylinder does not extend: (1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and manifold block. If full pressure reading but no cylinder movement plugged or defective holding valve. (2) Retract cylinder all the way, disconnect the hose going to the BASE END of the cylinders at the manifold. Carefully push the switch to RETRACT. If fluid comes out of the hose going to the base end of the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. 300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Truck Hitch (Optional) All Grayhound Pavers TRUCK HITCH WILL NOT RETRACT Engine at FULL THROTTLE. Truck hitch switch to the RETRACT position. Check for DIN connector light. If no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If truck hitch retracts, defective solenoid. If truck hitch does not retract: (1) Install a 3000 psi gauge in-line, between hose going to base end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Extend cylinder all the way, disconnect the hose going to the ROD END of the truck hitch cylinders at manifold. Carefully push switch to EXTEND. If fluid comes out of the hose going to the truck hitch cylinders, check cylinder for blown piston packing. If no fluid, install a 3000 psi gauge on test port of the truck hitch valve stack. Pressure should be 900 psi. If no pressure, defective solenoid. If low pressure, adjust. TRUCK HITCH DRIFTS OUT Engine at FULL THROTTLE Install a 3000 psi gauge on test port of the truck hitch valve stack. Truck hitch switch to RETRACT. Pressure should be 900 psi at end of stroke. If trucks are not staying aligned in front of the paver they can force oil over relief, causing the hitch to open. If this is not the case proceed with checks. Extend cylinders all the way, disconnect the hose going to the ROD END of the truck hitch cylinders at manifold. Carefully push switch to EXTEND. If fluid comes out of the hose going to the truck hitch cylinders, check cylinder for blown piston packing.

300 Series & CR411 Hydraulic Troubleshooting

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22479 (11/00)

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A Terex Company

Hopper Wings All Grayhound Pavers Hopper Wings

<<< Pressure <<<

Pressure Filter

.913 CID

Solenoid Valve Throttle Valve

Auxiliary Pump

Holding Valve

2050 RPM

2500 PSI

Restrictor

Test Port

200 Mesh Strainer

<<< Case Drain <<<

<<< Return <<<

Series: 300 *Full Load (RPM): 2100 *Max Flow (GPM): 8.4-11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

Manifold RH Front

AUXILIARY SYSTEM Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation (screed raise/lower, any extend/ retract function, pull point functions and etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings , damaged hose, or obstructions. HOPPER WINGS WILL NOT RAISE Engine at FULL THROTTLE. Hopper wing switch to the RAISE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If hopper wings raise, defective solenoid. If hopper wings DO NOT raise: (1) Install a 3000 psi gauge in-line, between the hose going to the rod end of the cylinder and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Disconnect the hose going to the base of the hopper cylinders at manifold. Carefully push the hopper switch to RAISE. If fluid comes out of the hose, check cylinders for blown piston packing. 300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Hopper Wings All Grayhound Pavers HOPPER WINGS WILL NOT LOWER Engine at FULL THROTTLE. Hopper wing switch to the LOWER position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If hopper wings lower, defective solenoid. If hopper wings do not lower, carefully crack the hose going to the base of the hopper cylinders. If hopper wings do not start to lower, check for bent or damaged cylinders. If hopper wings lower as fluid is bleed out of the hose, allow to go completely down. (1) Install a 3000 psi gauge in-line between the hose going to the base end of the cylinder and the manifold block. (2) Raise the hopper wings, then try to lower. If full pressure reading, but no cylinder movement, plugged or defective holding valve or plugged flow restrictor.

300 Series & CR411 Hydraulic Troubleshooting

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Technical Manual

A Terex Company

Track Tension Steel Track Pavers Tensioning Track

The track is designed to be virtually maintenance free. Proper cleaning and lubrication at the end of each paving day will maintain trouble free operation. However, neglect of the tracks can be expensive. Every time paver is cleaned, the track pins should be sprayed with light oil to lubricate them preventing them from rusting and binding.

If the track looks like it may be getting loose, it can be tested by placing a board or straight edge on the track between the front idler and the first top roller. If the gap between the bottom of the board and the top edge of the track is greater than 3¦4", the track tension must be adjusted. (Figure 2)

The Grayhound track paver uses a tension cylinder mounted above the final drive that maintains a constant volume of pressurized oil to the track adjusting cylinders. When the track encounters an obstacle, the system allows the tensioning idler to recoil rather than stretch or break the track. When the obstacle is cleared the system returns to the previous track tension adjustment.

3/4"

Figure 2 - Checking Track Tension

Important: Perform track tension checks and adjustments when the paver is at running temperature. Adjusting track tension when the paver is cold could lead to over-tensioning of the track.

1 3

Adjust track tension as follows:

4 5 From traction S charge pump

1) Start the engine.

T

2) Open the needle valve slowly to allow the track to retension. (Figure 4)

2

3) Drive the paver forward and backward slowly.

4 - Needle valve 1 - Counterbalance valve 2 - Rodless piston cylinder 5 - Idler tension cylinders 3 - Tensioning cylinder assy.

Warning: Be very careful when reaching over the moving track. Keep feet and loose clothing away from the moving track and rollers.

Figure 1 - Track tension hydraulic circuit

The track tensioning cylinder assembly consists of a cylinder with a rodless piston, a needle valve, and a counterbalance valve. (Figure 1) The piston keeps the oil from the idler tensioning cylinders separated from the main oil supply. When the track encounters an obstacle, it forces oil from the idler cylinders into the bottom side of the rodless cylinder. When the obstruction is cleared, pressurized oil from the traction charge pump forces the tensioning cylinder down which forces idler cylinders to move back to original position.

4) Stop the paver and close needle valve. 5) A properly tensioned track should have a 3¦8" to 1 ¦2" gap between a straightedge and the track. (Figure 3) 3/8" to 1/2"

Figure 3 - Proper Track Tension

The needle valve is used during track tensioning to bring the volume of oil on the bottom side of the rodless cylinder back to the proper level. The counterbalance valve allows oil to flow freely from the top side of the rodless cylinder to the tank when the track encounters an obstacle. 300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Track Tension Steel Track Pavers Warning: Overtightening the track can cause serious damage to the track, idler or drive.

7) If oil continues to flow into the bucket, the tension cylinder piston or needle valve is leaking and must be repaired.

Track over-pressurizing

8) Turn the engine off and reconnect the hydraulic line to the "T" port.

If the track adjusting system is over-pressurizing during operation, the following procedure must be performed. It is a good idea to perform this check once each season to verify the tensioning cylinder is in good condition.

Track Relief Pressure In addition to adjusting the track tension, the track relief pressure should be checked at least once each season. Check track relief pressure as follows:

Notice: Do not run the paver while the system is over-pressurized. Running with an overpressurized system could damage the track and sprockets.

1) Perform "Track over-pressurizing" procedure above. 2) Stop engine.

T

T

"T" Port

"T" Port Needle Valve

S

Needle Valve

S

Test Port Counter-Balance Valve

Tension Cylinder

Figure 5 - Checking Track Relief Pressure Setting

3) Close needle valve. 4) Bleed off pressure on tension cylinder by installing pressure gauge hose only onto test port and draining fluid into a bucket.

Figure 4 - Bottoming Tension Cylinder

1) Disconnect the line from the "T" port on the track tension cylinder. Install a plug into the disconnected line. (Figure 4)

5) Disconnect the line from the "T" port on the track tension cylinder. Install a plug into the disconnected line. (Figure 5)

2) Attach a drain line to the "T" port and run the other end into a bucket.

6) Install a 3000 PSI gauge on the hose which is connected to the tension cylinder test port.

3) Close the needle valve by rotating clockwise. 4) Start the engine and run at full throttle.

7) Connect a hand operated hydraulic pump to the "T" port on the tension cylinder.

5) If the track was tensioned properly, no oil will flow into the bucket.

8) Start and run engine at full throttle.

6) If only a small amount of oil drains into the bucket, the tension cylinder piston and needle valve are working properly and track will tension properly. 300 Series & CR411 Hydraulic Troubleshooting

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Track Tension Steel Track Pavers 9) Pump the hand pump to apply pressure to the counter balance valve. The counter balance valve will relieve the pressure generated by the pump at the track relief pressure setting. Note the pressure on the gauge when the counter balance valve relieves. 10) The track relief pressure setting should be 2050 psi +/- 100 psi. If pressure is outside this range, the counter balance valve requires adjustment. 11) To adjust track relief pressure: a) Loosen jam nut on counter balance valve. b) Rotate the valve counterclockwise to increase the pressure setting. Clockwise rotation will decrease the pressure setting. c) Tighten jam nut. 12) If the pressure can not be set, the counter balance valve is defective and must be replaced. Note - Replacement counter balance valves are factory set and should not require adjustment.

300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

300 Series & CR411 Hydraulic Troubleshooting

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22479 (11/00)

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A Terex Company

Rubber Track Hydraulic System

Rubber Track Hydraulic System

When the paver is started, oil is directed from the auxiliary pump to the track tension valves at 2500 psi. When tension pressure needs to be adjusted, oil is then routed to the piston side of the track tension cylinders by opening the tension valve charge cartridge needle valves allowing oil pressure to rise to 2500 psi. An accumulator for each track is placed in the circuit between the tension valve and the piston side of the track tensioning cylinders. The accumulator is pre-charged with dry nitrogen at 2250 psi to allow the track tension cylinders to retract and return if an impact is encountered.

The rubber track hydraulic system, see schematic, provides pressurized oil to the piston ends of track tension cylinders. Each track is independent and supplied by the auxiliary pump. Pressurized oil is held in the piston end of each track tension cylinder between tension valves and tension cylinders.

TRACK TENSION ACCUMULATOR

ACCUMULATOR CHARGE VALVES

TEST PORT

TRACK TENSION ACCUMULATOR

TEST PORT

TEST PORT TO OTHER <<<<<<<<<< AUXILIARY FUNCTIONS

PUMP INLET

CASE DRAIN

Rubber Track Hydraulic System Schematic

300 Series & CR411 Hydraulic Troubleshooting

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22479 (11/00)

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A Terex Company

Rubber Track Hydraulic System

Track Tension Valve Charge Cartridge

Test Port Accumulator

Track Tension Valve

Track Tension Valve Discharge Cartridge

Pressure To Tension Cylinder Track Tension Cylinder

45678

Rubber Track Hydraulic System Components

300 Series & CR411 Hydraulic Troubleshooting

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22479 (11/00)

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A Terex Company

Rubber Track Hydraulic System

8) The gauge reading at the point where it drops quickly to 0 psi should be 2250 psi at 68 degrees F. This reading may be slightly more or less depending the ambient temperature and the hydraulic system temperature.

Checking Rubber Track Hydraulic System The rubber track hydraulic system contains components which will automatically maintain track tension. To check out the system, follow the steps below:

9) If the accumulator dry nitrogen pre-charge is at 2250 psi, then tighten the discharge needle valve screw by turning it clockwise until snug on its seat.

Auxiliary System Pump Pressure First check the auxiliary pump pressure compensator adjustment to be sure the system is set to 2500 +/100 psi. See tractor O&M Manual for this procedure.

10) Re-tighten jam nut on discharge cartridge. 11) Charge the tension circuit to 2500 psi as described below.

Track Tension Accumulator

12) If the pressure is below 2250 psi when it drops quickly to 0 psi, re-charge the accumulator with dry nitrogen.

Check pre-charge of track tension accumulators on each side. 1) Install pressure gauge (3000 psi) at test port marked G on the Track Tension Valve. 2) Start and run engine at full throttle. 3) Pressure should read 2500 psi. 4) Shut engine off. Pressure on gauge should not change. 5) Loosen jam nut on discharge cartridge of track tension valve. 6) Insert an allen wrench into the adjusting screw, slowly turn it counter-clockwise to open the discharge needle valve and release hydraulic pressure while carefully watching the gauge. 7) The pressure reading should drop off slowly until it reaches the accumulator dry nitrogen precharge pressure. When the pressure reaches the accumulator pre-charge point, the gauge will drop quickly to 0 psi.

300 Series & CR411 Hydraulic Troubleshooting

13) If pressure is above 2250 psi, bleed off some dry nitrogen from the accumulator. 14) If the pressure drops steadily all the way to 0 psi and re-charging the accumulator does not work, then replace the accumulator.

Track Tension Pressure Check the track tension pressure on each side. 1) Install pressure gauge (3000 psi) at test port marked G on the Track Tension Valve. 2) Pressure should read 2500 psi.

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Rubber Track Hydraulic System

If pressure is not to 2500 psi, then do the following:

If pressure does not hold, do the following:

1) Start and run engine at full throttle. 2) Loosen jam nut on charge cartridge of track tension valve. 3) Insert an allen wrench into the adjusting screw, slowly turn it counter-clockwise to open the charge needle valve and allow hydraulic pressure to build to 2500 psi while carefully watching the gauge. 4) When the gauge reaches 2500 psi, close the charge needle valve by turning it clockwise until snug on its seat. 5) Shut off engine and note pressure.

1) Remove and cap lines from auxiliary pump-totension valve and from tension valve-to-tank. Caution: Escaping fluid under pressure can penetrate the skin causing serious injury. Be very careful when disconnecting hydraulic or other lines. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. Any fluid injected into the skin must be removed immediately by a doctor.

Pressure should hold at 2500 psi. Track Tension Valve Cartridges & Track Tension Cylinder If the track tension cylinder bounces during operation as if there is air in the lines, do the following: 1) Loosen jam nuts on both charge and discharge cartridges of track tension valve. 2) Start and run engine at full throttle. 3) Insert an allen wrench into the adjusting screws on the needle valves. 4) Alternately open and close each needle valve. Start with the discharge and then the charge. 5) Do step 4 until air is eliminated. 6) Tighten both needle valves snug on their seats. 7) Tighten jam nuts on each needle valve. 8) Shut off engine and note pressure.

From Auxiliary Pump To Tank To Tension Cylinder

Track Tension Valve Hydraulic Lines

Pressure should hold at 2500 psi. 2) Observe pressure on gauge.

300 Series & CR411 Hydraulic Troubleshooting

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Rubber Track Hydraulic System

Caution: Escaping fluid under pressure can penetrate the skin causing serious injury. Be very careful when disconnecting hydraulic or other lines. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. Any fluid injected into the skin must be removed immediately by a doctor.

3) If pressure drops from 2500 psi, observe which tension valve cartridge port (charge or discharge) is leaking hydraulic fluid. 4) Verify that both tension valve cartridge needle valves are completely shut as described above. 5) If one of the cartridge ports leaks, replace that cartridge. 6) If none of the cartridge ports is leaking, but the pressure still drops off, check the breather on the track tension cylinder. From Track Tension Valve

Track Tension Cylinder

Tension Cylinder Rod End Breather

Track Tension Cylinder

7) If hydraulic fluid is leaking from breather, the cylinder packing or cylinder wall may be damaged. Remove and repair or replace tension cylinder as necessary. 8) Remove caps from lines installed in Step 1 above and reinstall lines to tension valve.

300 Series & CR411 Hydraulic Troubleshooting

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Frame Raise Grayhound CR351/CR411 Pavers Rear Wheel Suspension

<<< Pressure <<<

Pressure Filter

<<< Return <<<

Series: 300 *Full Load (RPM): 2100 *Max Flow (GPM): 8.4-11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

Manifold Left Rear

200 Mesh Strainer

Auxiliary Pump

.913 CID

Solenoid Valve

2500 PSI

2050 RPM

<<< Case Drain <<<

Holding Valve

Test Port

AUXILIARY SYSTEM Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, pull point functions and etc.) If other functions work, this indicates the problem in only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to ensure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. FRAME WILL NOT RAISE Engine at FULL THROTTLE. Frame raise switch to the RAISE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If frame raises, defective solenoid. If frame does not raise: (1) Install a 3000 psi gauge in-line, between the hose going to the base end of the cylinders and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Extend cylinder all the way, disconnect the hose going to the BASE END of the cylinder. Carefully push the frame switch to RAISE. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. 300 Series & CR411 Hydraulic Troubleshooting

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Frame Raise Grayhound CR351/CR411 Pavers FRAME WILL NOT LOWER Engine at FULL THROTTLE. Frame switch to the LOWER position. Check for DIN connector light. If no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If frame lowers, defective solenoid. If frame does not lower: (1) Install a 3000 psi gauge in-line, between the hose going to the rod end of the cylinder and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Retract cylinder all the way, disconnect the hose going to the ROD END of the frame cylinder. Carefully push the frame switch to lower, If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. FRAME DRIFTS DOWN Engine at FULL THROTTLE Check DIN connectors for lights. If any light on, electrical system is telling the cylinder to move. If no lights are flashing on, proceed with checks. Retract cylinder all the way, disconnect the hose going to the BASE END of the frame cylinders. Carefully push the frame switch to RAISE. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective holding valve. FRAME LOWERS TOO QUICKLY Plugged or defective throttle valve.

300 Series & CR411 Hydraulic Troubleshooting

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Frame Raise Grayhound CR361 Pavers REAR WHEEL SUSPENSION

PRESSURE FILTER TEST PORT

Series: 361 *Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage.

FLOW DIVIDER

HOLDING VALVE

.913 CID

2500 PSI

2500 RPM

THROTTLE VALVE

AUXILIARY PUMP

SOLENOID VALVE MANIFOLD LH REAR

200 MESH STRAINER

AUXILIARY SYSTEM Check hydraulic fluid level. HYDRAULIC TANK Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, pull point functions and etc.) If other functions work, this indicates the problem in only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to ensure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. FRAME WILL NOT RAISE Engine at FULL THROTTLE. Frame raise switch to the RAISE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If frame raises, defective solenoid. If frame does not raise: (1) Install a 3000 psi gauge in-line, between the hose going to the base end of the cylinders and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Retract cylinder all the way, disconnect the hose going to the BASE END of the cylinder. Carefully push the frame switch to RAISE. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. 300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Frame Raise Grayhound CR361 Pavers FRAME WILL NOT LOWER Engine at FULL THROTTLE. Frame switch to the LOWER position. Check for DIN connector light. If no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If frame lowers, defective solenoid. If frame does not lower: (1) Install a 3000 psi gauge in-line, between the hose going to the rod end of the cylinder and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Retract cylinder all the way, disconnect the hose going to the ROD END of the frame cylinder. Carefully push the frame switch to lower, If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. FRAME DRIFTS DOWN Engine at FULL THROTTLE Check DIN connectors for lights. If any light on, electrical system is telling the cylinder to move. If no lights are flashing on, proceed with checks. Retract cylinder all the way, disconnect the hose going to the BASE END of the frame cylinders. Carefully push the frame switch to RAISE. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective holding valve. FRAME LOWERS TOO QUICKLY Plugged or defective throttle valve. ONE SIDE RAISES SLOWER OR NOT AT ALL (1) Lower frame raise. (2) Bypass flow divider. (3) Push frame raise switch to raise. Both sides should raise at the same speed although one side may stop raising while other side continues to raise. If both sides move at same speed, plugged or defective flow divider.

300 Series & CR411 Hydraulic Troubleshooting

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Screed Lift All Grayhound Pavers with Fastach Screeds Screed Lift

Holding Valve

2050 RPM

.913 CID

Solenoid Valve

Series: 300 *Full Load (RPM): 2100 *Max Flow (GPM): 8.4-11.0 Pressure (PSI): 2500 *Varies depending on vintage. 200 Mesh Strainer

<<< Case Drain <<<

>>> Suction >>>

Manifold LH Rear

Auxiliary Pump

Restrictor

Test Port

2500 PSI

<<< Pressure <<<

<<< Return <<<

Pressure Filter

AUXILIARY SYSTEM Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, pull point functions, etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. SCREED LIFT WILL NOT RAISE Engine at FULL THROTTLE. Screed lift switch to the RAISE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If screed lift raises, defective solenoid. If screed lift does not raise: (1) Install a 3000 psi gauge in-line, between the hose going to the rod end of the cylinder and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Disconnect hoses from Base end of the screed lift cylinders. Carefully push the screed lift switch to RAISE. If fluid comes out of the fitting on the cylinders, check cylinder for blown piston packing. 300 Series & CR411 Hydraulic Troubleshooting

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Screed Lift All Grayhound Pavers with Fastach Screeds SCREED LIFT WILL NOT LOWER Engine at FULL THROTTLE. Screed lift switch to the LOWER position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If screed lift lowers, defective solenoid. If screed lift does not lower, check for plugged flow restrictor or defective solenoid valve.

300 Series & CR411 Hydraulic Troubleshooting

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Screed Assist All Grayhound Pavers

175 PSI Nitrogen Precharge

Optional Screed Assist (Suppled with Extendable Screed)

Screed Lift

E

Pressure Filter

Holding Valve I

2050 RPM

T

.913 CID

Solenoid Valve

200 Mesh Strainer

<<< Case Drain <<<

Series: 300 *Full Load (RPM): 2100 *Max Flow (GPM): 8.4-11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

Manifold LH Rear

Auxiliary Pump

Restrictor

Test Port

2500 PSI

D

<<< Pressure <<<

V

AUXILIARY SYSTEM Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation, (screed raise/lower, any extend/ retract function, tow-point functions, etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. SCREED LIFT WILL NOT RAISE Engine at FULL THROTTLE. Screed assist switch OFF. Screed lift switch to the RAISE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If screed lift raises, defective solenoid. If screed lift does not raise: (1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Disconnect hoses from base end of the screed lift cylinders. Carefully push the screed lift switch to RAISE. If fluid comes out of the fitting on the cylinders, check cylinder for blown piston packing.

300 Series & CR411 Hydraulic Troubleshooting

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Screed Assist All Grayhound Pavers SCREED LIFT WILL NOT LOWER Engine at FULL THROTTLE. Screed assist switch OFF. Screed lift switch to the LOWER position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If screed lift lowers, defective solenoid. If screed lift does not lower, check for plugged flow restrictor or defective solenoid valve. SCREED ASSIST WILL NOT COME ON Engine at FULL THROTTLE. Screed lift switch in LOWER. Screed assist switch ON. Place a small screw driver next to the top of the screed assist solenoid valve. If no magnetic field is felt, refer to electrical troubleshooting. If solenoid attracts screw driver continue with checks: Install a 2000 psi gauge in-line at the ROD end of the screed lift cylinder (either cylinder). Pressure should read same as gauge mounted on bottom of accumulator. If pressure is lower, defective solenoid valve. With gauge in same place, adjust screed assist pressure reducing valve clockwise. The pressure readings should increase. If no increase, defective pressure reducing valve. The working pressure is 200 to 600 psi on the screed assist system. SCREED ASSIST SYSTEM PRESSURE IS NOT STABLE Run checks listed above. Shut machine OFF. OPEN manual dump valve to bleed all pressure from system. Check accumulator for 175 psi pre charge. If no pre-charge remove hose from bottom of accumulator, charge cylinder and listen for blown bladder. REMOVING SCREED ASSIST FROM SYSTEM & CHECKING SCREED LIFT CYLINDERS Shut machine OFF. OPEN manual dump valve to bleed all pressure from the system. Disconnect hoses from ports E and V on screed assist manifold. Connect the two hoses together. Plug ports E and V on screed assist manifold to prevent entry of debris. Engine at FULL THROTTLE. Screed lift switch in RAISE position. If screed lowers, defective screed lift cylinder packings.

300 Series & CR411 Hydraulic Troubleshooting

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Tow Point All Grayhound Pavers Pull Point

.913 CID

Solenoid Valve

Series: 300 *Full Load (RPM): 2100 *Max Flow (GPM): 8.4-11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

Manifold RH Front

200 Mesh Strainer

Auxiliary Pump

Dual Throttle Valve

2050 RPM

2500 PSI

Holding Valve

Test Port

<<< Case Drain <<<

<<< Pressure <<<

Pressure Filter

AUXILIARY SYSTEM Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point functions and etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for lose fittings, damaged hose, or obstructions. TOW POINT WILL NOT INCREASE Engine at FULL THROTTLE. Tow point increase/decrease switch to the INCREASE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If tow point cylinder increases, defective solenoid. If tow point cylinder does not increase: (1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Extend cylinder all the way, disconnect the hose going to the ROD END of the tow point cylinder. Carefully push the increase/decrease switch to DECREASE. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. 300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Tow Point All Grayhound Pavers TOW POINT WILL NOT DECREASE Engine at FULL THROTTLE. Tow point increase/decrease switch to the DECREASE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If tow point cylinder decreases, defective solenoid. If tow point cylinder does not decrease: (1) Install a 3000 psi gauge in-line, between hose going to base end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Retract cylinder all the way, disconnect the hose going to the BASE END of the tow point cylinder. Carefully push the increase/decrease switch to INCREASE, If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. TOW POINT CYLINDER DRIFTS UP OR DOWN Engine at FULL THROTTLE Check DIN connectors for lights, If any light on, electrical system is telling the cylinder to move. If no lights are flashing on, proceed with checks. Extend cylinder all the way, disconnect the hose going to the ROD END of the tow point cylinder. Carefully push the increase/decrease switch to DECREASE, if fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective holding valve.

300 Series & CR411 Hydraulic Troubleshooting

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Main Screed Power Crown All Grayhound Pavers POWER CROWN (OPTIONAL)

P

T

Test Port 2050 RPM

.913 CID P

Auxiliary Pump

B

2500 PSI

A

<<< Pressure <<<

Pressure Filter

200 Mesh Strainer

<<< Case Drain <<<

Series: 300 *Full Load (RPM): 2100 *Max Flow (GPM): 8.4-11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

T

AUXILIARY SYSTEM Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point functions and etc.) If other functions work, this indicates the problem in only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to ensure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose for lose fittings, damaged hose, and obstructions. CROWN WILL NOT INCREASE Engine at FULL THROTTLE. Crown increase/decrease switch to the INCREASE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If crown increases, defective solenoid. If crown does not move, disconnect hose from port B of the manifold valve. Crown switch to INCREASE, if oil comes out of hose and crown does not move, defective motor. If no oil, reconnect hose and install 3000 psi gauge between port A and hose A. Crown switch to INCREASE, if pressure, check for interference on mechanical components or defective motor. 300 Series & CR411 Hydraulic Troubleshooting

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Main Screed Power Crown All Grayhound Pavers CROWN WILL NOT DECREASE Engine at FULL THROTTLE. Crown increase/decrease switch to the DECREASE position. Check for DIN connector light, if NO light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If crown increases, defective solenoid. If crown does not move, disconnect hose from port A of the manifold valve. Crown switch to DECREASE, if oil comes out of hose and crown does not move, defective motor. If no oil, reconnect hose and install 3000 psi gauge between port B and hose B. Crown switch to DECREASE. If pressure, check for interference on mechanical components or defective motor.

300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Screed Extend 8 - 14 Screed Pressure Return

AUXILIARY SYSTEM Check hydraulic fluid level. Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point functions, etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. SCREED WILL NOT EXTEND Engine at FULL THROTTLE Push manual control valve lever to extend position. If lever can not be moved, defective valve. Install a 3000 psi gauge in-line on the base end of the screed extend cylinder, If no pressure, defective manual control valve OK pressure relief. Remove hose from rod end of cylinder, if oil comes out rod end port, blown piston packing. SCREED WILL NOT RETRACT Engine at FULL THROTTLE Push manual control valve lever to retract position. If lever cannot be moved, defective valve. Install a 3000 psi gauge in-line on the rod end of the screed extend cylinder. If no pressure, defective control valve or pressure relief. Remove hose from base end of cylinder, if oil comes out rod end port, blown piston packing. 300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Screed Extend Fastach 8’ Screed Series: 300 *Full Load (RPM): 2100 *Max Flow (GPM): 8.4-11.0 Pressure (PSI): 2500 *Varies depending on vintage.

LH Extend Cylinder

2000 PSI

2000 PSI

Test Port 2050 RPM

5/64" Dia.

200 Mesh

<<< Case Drain <<<

B

>>> Suction >>>

A

.913 CID

Auxiliary Pump

Counterbalance Valve

2500 PSI

<<< Pressure <<<

Pressure Filter

Strainer AUXILIARY SYSTEM Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point functions, etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions.

SCREED WILL NOT EXTEND Engine at FULL THROTTLE Tow manual control valve lever to extend position. If lever can not be moved, defective valve. Install a 3000 psi gauge in-line on the base end of the screed extend cylinder, If no pressure, plugged flow restrictor. If system pressure, defective counterbalance valve. Remove hose from rod end of cylinder, if oil comes out rod end port, blown piston packing. SCREED WILL NOT RETRACT Engine at FULL THROTTLE Push manual control valve lever to retract position. If lever cannot be moved, defective valve. Install a 3000 psi gauge in-line on the rod end of the screed extend cylinder. If no pressure, plugged flow restrictor. If system pressure, defective counterbalance valve. Remove hose from base end of cylinder, if oil comes out rod end port, blown piston packing. 300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Vibrator Fastach 8’ Screed

>>Suction>>

<
<< Pressure <<

200 Mesh Strainer

VIBRATORS WILL NOT COME ON Engine at FULL THROTTLE. Brakes RELEASED. Vibrator switch ON. Travel lever FORWARD. Vibrator speed valve turned clockwise all the way. Check vibrator DIN connector for light. If no light refer to electrical. If light is ON: (1) Refer to electrical for testing ground connection. (2) Place a small screw driver next to the solenoid, if no magnetic field is felt refer to electrical. If magnetic field is present, proceed with checks: Turn vibrator shaft by hand, It should turn freely with little resistance. If it can not be turned by hand, check for mechanical failure or bind. If only one shaft vibrates, defective motor on one that does not. Install a 3000 psi gauge in test port, Unplug quick couplings from rear bulk head. Pressure should be 1500 psi. If no pressure, check pump. If low pressure, defective solenoid valve If pressure is correct, reconnect quick couplings. Check pressure, if pressure is 1500 psi, defective flow divider. Remove return hose from vibrator speed valve and cap hose. If a great amount of oil comes out speed valve port, defective speed valve. 300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Vibrator Fastach 10’ Screed

>> Suction >>

<< Return <<

<< Pressure <<

200 Mesh Strainer

VIBRATORS WILL NOT COME ON Engine at FULL THROTTLE. Brakes RELEASED. Vibrator switch ON. Travel lever FORWARD. Vibrator speed valve turned clockwise all the way. Check vibrator DIN connector for light. If no light refer to electrical. If light is ON: (1) Refer to electrical for testing ground connection. (2) Place a small screw driver next to the solenoid, if no magnetic field is felt refer to electrical. If magnetic field is present, proceed with checks: Turn vibrator shaft by hand, It should turn freely with little resistance. If it can not be turned by hand, check for mechanical failure or bind. Install a 3000 psi gauge in test port. Unplug quick couplings from rear bulk head. Pressure should be 1500 psi. If no pressure, check pump. If low pressure, defective solenoid valve If pressure is correct, reconnect quick couplings. Remove case drain hose from motor and cap hose. If a great amount of oil is coming out of case drain port, the motor is bad. If very little oil comes out of case drain, disconnect return hose from vibrator speed valve and cap hose. If great amount of oil comes out of return port on speed valve, defective speed valve. 300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Vibrators 8-14 Screed Return

Pressure Speed Control Valve

Motor

Flow Divider

Motor

Motor

VIBRATORS WILL NOT COME ON Engine at FULL THROTTLE. Brakes RELEASED. Vibrator switch ON. Travel lever FORWARD. Vibrator speed valve turned clockwise all the way. Check vibrator DIN connector for light. If no light refer to electrical. If light is ON: (1) Refer to electrical for testing ground connection. (2) Place a small screw driver next to the solenoid, if no magnetic field is felt refer to electrical. If magnetic field is present, proceed with checks: Turn vibrator shafts by hand, They should turn freely with little resistance. If it can not be turned by hand. Check for mechanical failure or bind. If all but one vibrator is turning, check for defective motor on the one that is not turning, install a 3000 psi gauge in test port. Unplug quick couplings from rear bulk head. Pressure should be 1500 psi. If no pressure, check pump. If low pressure, defective solenoid valve If pressure is correct, reconnect quick couplings. Disconnect return hose from vibrator speed valve and cap hose. If great amount of oil comes out of return port on speed valve, defective speed valve. 300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Conveyor Grayhound 300 Series

33.6 GPM Max

390 PSI

2.8 CID

2100 RPM Max.

<< Case Drain <<

>> Suction >>

<< Case Drain <<

2.8 1.4 CID CID

10 µ ß2 Filter

Hydraulic Tank

CONVEYOR DOES NOT WORK Refer to conveyor electrical troubleshooting checks. Engine at FULL THROTTLE. Push manual override lever in both directions, (one direction will turn the conveyor in forward, the other will turn the conveyor in reverse.) If conveyor does not move in either direction, check pump drive for damaged splines. If drive is ok, install a 600 psi gauge on High pressure test port. Pressure reading will be charge pressure. (Do not engage conveyor) Charge pressure is 400 psi. If no or low pressure reading, refer to pump service manual. If pressure is ok, install a 6000 psi gauge in the conveyor high pressure test port. Block or chain conveyor to prevent turning. Conveyor switch to manual. Pressure reading should be 3045 psi. If no or low pressure reading, refer to pump service manual. If pressure is OK, check for over loading auger conveyor system (Head of material in auger chamber) chain adjustments or mechanical binds. CONVEYOR STALLS WHEN UNDER LOAD Block or chain conveyor to prevent turning. Engine at FULL THROTTLE. Install a 6000 psi gauge in the high pressure test port. Conveyor switch to MANUAL. Pressure reading should be 3045 psi. If low pressure reading, refer to pump service manual. If pressure is OK, check for over loading auger conveyor system (Head of material in auger chamber) chain adjustments or mechanical binds. 300 Series & CR411 Hydraulic Troubleshooting

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300 Series & CR411 Hydraulic Troubleshooting

40

22479 (11/00)

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A Terex Company

Conveyor Grayhound CR411

33.6 GPM Max

390 PSI

29.9 CID

230 RPM Max.

2.8 1.4 CID CID

Note: High Pressure Relief: 3400 PSI Charge Pressure 400 PSI

10 µ ß2 Filter

Cooler

Hydraulic Tank

CONVEYOR DOES NOT WORK Refer to conveyor electrical troubleshooting checks. Engine at FULL THROTTLE. Push manual override lever in both directions, (one direction will turn the conveyor in forward, the other will turn the conveyor in reverse.) If conveyor does not move in either direction, check pump drive for damaged splines. If drive is ok, install a 600 psi gauge on High pressure test port. Pressure reading will be charge pressure. (Do not engage conveyor) Charge pressure for 400 & 500 series 330 psi, 300 series is 400 psi. If no or low pressure reading, refer to pump service manual. If pressure is ok, install a 6000 psi gauge in the conveyor high pressure test port. Block or chain conveyor to prevent turning. Conveyor switch to manual. Pressure reading should be 3800 psi on 400 & 500 series, and 3045 psi on 300 series. If no or low pressure reading, refer to pump service manual. If pressure is OK, check for over loading auger conveyor system (Head of material in auger chamber) chain adjustments or mechanical binds. CONVEYOR STALLS WHEN UNDER LOAD Block or chain conveyor to prevent turning. Engine at FULL THROTTLE. Install a 6000 psi gauge in the high pressure test port. Conveyor switch to MANUAL. Pressure reading should be 3800 psi on 400 & 500 series, and 3045 psi on 300 series. If low pressure reading, refer to pump service manual. If pressure is OK, check for over loading auger conveyor system (Head of material in auger chamber) chain adjustments or mechanical binds.

300 Series & CR411 Hydraulic Troubleshooting

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A Terex Company

Traction System/Differential Lock Grayhound 300 Series

Differental Lock

LH Traction Drive Parking Brake

To RH Traction System (Rubber Tire Only)

Charge Pressure LH Traction Pump

Range Shift

390 PSI 2500 RPM 2.8 1.4 CID CID

200 Mesh Strainer Hydraulic Tank

TRACTION SYSTEM WILL NOT WORK (Refer to traction electrical troubleshooting.) TRACTION SYSTEM TOWS TO ONE SIDE ONLY Refer to traction electrical troubleshooting. Disconnect and cap cross over lines and ports between LH & RH FORWARD & REVERSE HIGH PRESSURE PORTS ON CR351 MODELS. Install 600 psi gauges in FORWARD & REVERSE high pressure test ports, on side that is not towing. Engine at FULL THROTTLE. Pressure should be 350 psi and within 40 psi of each other. If low refer to pump service manual. If charge pressure cannot be adjusted, disconnect case drain hose and check for oil flow from motor. If oil is flowing out of motor, disconnect high pressure hoses (forward & reverse) to motor & cap. Recheck charge pressure. If pressure is ok, refer to motor service manual. If pressure still low, refer to pump service manual. If pressure greater than 40 psi of each other, refer to pump service manual for pump centering. Install 6000 psi gauges in the FORWARD & REVERSE high pressure test ports. Unplug Brake DIN connector from brake solenoid valve. (this will lock up the brakes) Brake switch to OFF.

300 Series & CR411 Hydraulic Troubleshooting

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Traction System/Differential Lock Grayhound 300 Series Travel speed pot to 10. Engine at FULL THROTTLE. Travel lever or lever on slow side, FORWARD. Then lever to REVERSE. Pressure should be 5400 psi. If low refer to pump service manual. Push manual override in each direction. Pressure should be 5400 psi. If low refer to pump service manual. DIFFERENTIAL LOCK DOES NOT FUNCTION Check DIN connector light If no light, refer to electrical troubleshooting If light is on (1) refer to electrical troubleshooting for ground connection. (2) If valve has a good ground and differential lock does not function, replace valve.

300 Series & CR411 Hydraulic Troubleshooting

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Traction System Grayhound CR411 LH Traction Drive Parking Brake

Charge Pressure LH Traction Pump

Range Shift

390 PSI 2100 RPM 2.8 1.4 CID CID

50.4 Ratio

10µ ß2 Filter

33.6 GPM Max Cooler

Hydraulic Tank

TRACTION SYSTEM WILL NOT WORK (Refer to traction electrical troubleshooting.) TRACTION SYSTEM TOWS TO ONE SIDE ONLY Refer to traction electrical troubleshooting. Disconnect and cap cross over lines and ports between LH & RH FORWARD & REVERSE high pressure ports on CR351 models. Install 600 psi gauges in FORWARD & REVERSE high pressure test ports, on side that is not towing. Engine at FULL THROTTLE. Pressure should be 350 psi and within 40 psi of each other. If low refer to pump service manual. If charge pressure cannot be adjusted, disconnect case drain hose and check for oil flow from motor. If oil is flowing out of motor, disconnect high pressure hoses (forward & reverse) to motor & cap. Recheck charge pressure. If pressure is ok, refer to motor service manual. If pressure still low, refer to pump service manual. If pressure greater than 40 psi of each other, refer to pump service manual for pump centering. Install 6000 psi gauges in the FORWARD & REVERSE high pressure test ports. Unplug Brake DIN connector from brake solenoid valve. (this will lock up the brakes) Brake switch to OFF. Travel speed pot to 10. Engine at FULL THROTTLE. Travel lever or lever on slow side, FORWARD. Then lever to REVERSE. Pressure should be 5400 psi. If low refer to pump service manual. Push manual override in each direction. Pressure should be 5400 psi. If low refer to pump service manual. 300 Series & CR411 Hydraulic Troubleshooting

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Front Wheel Assist (Optional) All Grayhound Rubber Tire Pavers

FROM TRACTION PUMP DRIVE MOTOR

>>CASE DRAIN>>

FRONT WHEEL ASSIST 4WD PILOT VALVE

FROM TRACTION PUMP

DRIVE MOTOR

>> CASE DRAIN >>

FRONT WHEEL ASSIST (P4) The front wheel assist system should not be confused with or considered as a four wheel drive system. When the front wheel assist solenoid valve is energized pressure is applied to separate 5 way valves. When the 5way valves are open, pressure from the main traction pump is applied to both the main drive motor and the front wheel assist motor on that side of the machine. The amount of tractive effort increase will depend on the amount of traction the front wheels have in a given ground condition. FRONT WHEEL ASSIST WILL NOT ENGAGE Engine at FULL THROTTLE. Travel/P2/P4 switch to P4. Check front wheel assist solenoid valve DIN connector for light. If NO light, refer to electrical troubleshooting. If light is ON, (1) Refer to electrical troubleshooting for ground connection (2) Install a 600 psi gauge in the LH conveyor high pressure test port. (Do not engage conveyor) Refer to conveyor charge pressure above for pressure required. If pressure is low, refer to conveyor. (3) If pressure is correct, install 600 psi gauge between A port and hose going to the 5 way valves. If no or low pressure, defective solenoid valve. (4) If pressure is correct, install 6000 psi gage between 5-way valve and motor. Move machine. If very low or no pressure, defective 5-way valve on that side. Both sides will need to be checked. 300 Series & CR411 Hydraulic Troubleshooting

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300 Series & CR411 Hydraulic Troubleshooting

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PAVER TECHNICAL MANUAL

400 & 500 Series Electrical Section

Technical Manual

A Terex Company

Table of Contents 400 & 500 Series Electrical Section Component Location Map ............................................................................................ 1 - 16 Engine Starting System ..................................................................................................... 17 Charging System................................................................................................................ 18 Throttle & Fuel ........................................................................................................... 19 - 20 Engine Start & Fuel - Elite Engine .................................................................................... 21 Horn ................................................................................................................................... 22 Gauges ............................................................................................................................... 23 Lights ................................................................................................................................. 24 Brakes ................................................................................................................................ 25 Travel Pave (P2) System .................................................................................................... 26 Front Wheel Assist CR451 and CR551 ............................................................................. 27 Travel Control CR451 and CR551 ............................................................................. 28 - 30 Travel Control & Steer Assist - Rubber Tire Pavers 1999 & After ............................. 31 - 33 Travel Control Adj. Procedure 3 Pot Controller Tire Pavers ...................................... 34 - 35 Travel Control Adj. Procedure 3 Pot Controller Track Pavers .................................... 36 - 38 Travel Control Adj. Procedure Tire Pavers w/Lever Controls .................................... 39 - 40 Differential Lock CR451 and CR551 ................................................................................ 41 Steer Assist CR451 and CR551 .................................................................................. 42 - 43 LH Travel Speed Control CR461 and CR561 ............................................................ 44 - 45 RH Travel Speed Control CR461 and CR561 ............................................................ 46 - 47 Travel Control Adj. Procedure Track Pavers w/Lever Controls ................................. 48 - 50 Susmic 10 Dual Path Control Calibration Procedures ................................................ 51 - 55 Hopper ............................................................................................................................... 56 Truck Hitch (Optional) ...................................................................................................... 57 Frame Raise ....................................................................................................................... 58 LH Flow Gate .................................................................................................................... 59 RH Flow Gate .................................................................................................................... 60 Material Flow Indicators 1999 & Before .................................................................... 61 - 62 Material Flow Indicators 1999 & After ...................................................................... 63 - 64 Screed Lift ......................................................................................................................... 65 Screed Assist ...................................................................................................................... 66 Power Main Crown ............................................................................................................ 67 400 & 500 Series Electrical Troubleshooting

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Table of Contents 400 & 500 Series Electrical Section LH Screed Extend Stretch 20 & Fastach 10 Hydraulic Strike-Off .................................... 68 RH Screed Extend Stretch 20 & Fastach 10 Hydraulic Strike-Off .................................... 69 LH Screed Slope Stretch 20 & Fastach 10 Hydraulic Strike-Off ...................................... 70 RH Screed Slope Stretch 20 & Fastach 10 Hydraulic Strike-Off ...................................... 71 LH Match Height Stretch 20 ............................................................................................. 72 RH Match Height Stretch 20 ............................................................................................. 73 Vibrators ............................................................................................................................ 74 LH Main Burner #1 ........................................................................................................... 75 RH Main Burner #2 ........................................................................................................... 76 LH Ext. Burner #3 ............................................................................................................. 77 RH Ext. Burner #4 ............................................................................................................. 78 Rear Frame Compensator Adjustment ............................................................................... 79

400 & 500 Series Electrical Troubleshooting

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Component Location Map Fastach 10' Grayhound 400 & 500 Series

L33 L34 L32

L35

L31

L37 L36

L39 L38

L31 ....... LH extend/retract solenoid L32 ....... LH slope solenoid L33 ....... Slope control module L34 ....... Controls for glow plugs, fans, crown and horn L35 ....... Burner and spray down control valves L36 ....... RH slope solenoid L37 ....... RH extend/retract solenoid L38 ....... LH screed burner fan and glow plug L39 ....... RH screed burner fan and glow plug

400 & 500 Series Electrical Troubleshooting

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Component Location Map Fastach II

2

Cedarapids EXTEND

FEED OVER RIDE

STOP

SLOPE

MATCH

HEIGHT

BERM

TOWPOINT MAN MAN SETUP AUTO HORN

Cedarapids EXTEND

FEED OVER RIDE

STOP

SLOPE E TEMPERATUR RH MAIN

MATCH

RH EXT

HEIGHT LH MAIN LH EXT

CONTROL

HEAT

OUTLET

HEAT

OUTLET

HEAT

HEAT HEAT

BERM

GENERATOR ON

OFF

ON

OFF

TOWPOINT MAN MAN SETUP AUTO HORN

HORN

CROWN E

INCREAS

DECREAS

E

1

1 ........... Screed Heater Control Panel 2 ........... Screed Generator

400 & 500 Series Electrical Troubleshooting

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Component Location Map Fastach 10' & Stretch 20 Grayhound 400 & 500 Series

L22

L20 L18

L23

L24

L21 L19

L26 L25

L30 L29

L28 L27

L18 ....... LH extend/retract solenoid L19 ....... LH match height solenoid L20 ....... LH slope solenoid L21 ....... Crown solenoid L22 ....... RH slope solenoid L23 ....... RH match height solenoid L24 ....... RH extend/retract solenoid L25 ....... LH remote control switch assembly L26 ....... RH remote control switch assembly L27 ....... LH extension burner fan and glow plug L28 ....... LH main screed burner fan and glow plug L29 ....... RH main screed burner fan and glow plug L30 ....... RH extension burner fan Note: L25, L26, L33, L34 and L35 are the same on both the Fastach 10' and Stretch 20 screeds. 400 & 500 Series Electrical Troubleshooting

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Component Location Map Grayhound 400 & 500 Series

DIN Connector

Earlier Version Travel Controller

Low Threshold Manual Override

Reverse Maximum Pot Forward Maximum Pot

DIN Connector

Current Version Travel Controller

MINIMUM Forward Pot

MINIMUM Reverse Pot MAXIMUM Forward Pot MAXIMUM Reverse Pot

400 & 500 Series Electrical Troubleshooting

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Component Location Map Grayhound 400 & 500 Series L4

L2 L1

L3

L5

L6

Front Bulkhead L17 L9

L12

L8 L7

L16 L11

L13

L10

Rear Bulkhead

L14 L15

L1 ......... Slope sensor L2 ......... Front wheel assist L3 ......... LH pull point solenoid L4 ......... Truck hitch solenoid L5 ......... LH material flow gate L6 ......... RH material flow gate L7 ......... Main electrical junction box L8 ......... Hopper wing solenoid L9 ......... RH pull point solenoid L10 ....... Screed lift solenoid L11 ....... Frame raise solenoid L12 ....... Brake solenoid L13 ....... Vibrator solenoid L14 ....... LH feed sensor L15 ....... RH feed sensor L16 ....... Travel/Pave solenoid L17 ....... Burner/Spraydown pump & motor

400 & 500 Series Electrical Troubleshooting

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Component Location Map Grayhound 400/500 Series Digital Display

L44

L42 L43 L40

L46 L45

L41

L47

L48

L49

L50

L54 L51 L53

L40 ....... Master key L41 ....... Detroit governor card/feeder resistor card L42 ....... 60 amp breaker (burner) L43 ....... 15 amp breaker (power) L44 ....... 15 amp breaker (control) L45 ....... 15 amp breaker (flasher) L46 ....... 15 amp breaker (Lights) L47 ....... RH flow gate relay (lower)

400 & 500 Series Electrical Troubleshooting

6

L48 ....... LH flow gate relay (raise) L49 ....... RH flow gate relay (lower) L50 ....... LH flow gate relay (raise) L51 ....... Proportional module L52 ....... Horn relay L53 ....... Terminal block L54 ....... Murphy timer relay

22480 (10/01)

Technical Manual

A Terex Company

Component Location Map Grayhound 400/500 Series Digital Display L55 L56

L57

L58

L60

L76

L59 L62 L63 L65 L66 L68

L61 L64 L67 L70

L69

L71 L72 L73

L76

L74

L55 .......... Lights L56 .......... Vibrator L57 .......... Frame raise L58 .......... Strobe light L59 .......... Horn L60 .......... Screed lift L61 .......... Screed assist L62 .......... RH flow gate L63 .......... LH flow gate L64 .......... Brake L65 .......... RH conveyor speed 400 & 500 Series Electrical Troubleshooting

L75

L66 .......... LH conveyor speed L67 .......... Travel/Pave (travel/P2/P4) L68 .......... RH conveyor manual/auto L69 .......... LH conveyor manual/auto L70 .......... Engine start/run/stop L71 .......... Truck hitch L72 .......... Hopper L73 .......... Throttle L74 .......... Digital meter L75 .......... Travel speed pot L76 .......... Travel lever(s) 7

22480 (10/01)

Technical Manual

A Terex Company

Component Location Map 1st Generation Version Grayhound 400/500 Series Analog Display

13 12 11 10

9 8

7

6

5

4

3

2

1

14

15 16

1 ........... Timing relay 2 ........... Engine breaker 15 amp 3 ........... Light breaker 15 amp 4 ........... Flasher breaker 15 amp 5 ........... Control breaker 15 amp 6 ........... Power breaker 30 amp 7 ........... Burner breaker 60 amp 8 ........... Spare relay 9 ........... K3 relay 10 ......... K15 relay 11 ......... K16 relay 12 ......... K17 relay 13 ......... K18 relay 14 ......... RH auger/conveyor proportional module 15 ......... LH auger/conveyor proportional module 16 ......... K1 relay

400 & 500 Series Electrical Troubleshooting

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Component Location Map 1st Generation Version Grayhound 400/500 Series Analog Display 8

7

6

5

9 10 11 13 17 18

4

3

12

2

1

11

15 16

21

23 22

19 26

20

25 24

1 ........... Travel control(s) 2 ........... Travel speed pot 3 ........... Truck hitch switch 4 ........... Hopper wing switch 5 ........... RH conveyor switch 6 ........... LH conveyor switch 7 ........... Travel range switch 8 ........... Throttle switch 9 ........... Brake 10 ......... Engine stop/start/run switch 11 ......... LH conveyor speed pot 12 ......... RH conveyor speed pot 13 ......... Horn switch 400 & 500 Series Electrical Troubleshooting

14 ......... Vibrator switch 15 ......... RH flow gate switch 16 ......... LH flow gate switch 17 ......... Screed lift switch 18 ......... Screed assist switch 19 ......... Light switch 20 ......... Flasher switch 21 ......... Oil temperature gauge 22 ......... Water temperature gauge 23 ......... Tachometer 24 ......... Volt meter 25 ......... Fuel level gauge 26 ......... Oil pressure gauge 9

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Technical Manual

A Terex Company

Component Location Map 2nd Generation Version Grayhound 400/500 Series Analog Display 24 23 22 21 20 19 18 17 16 15 1 2 3 4 5 6 7 8 9

12 14

13 10

11

1 ........... Engine breaker: 15 amp 2 ........... Screed breaker: 15 amp 3 ........... Control breaker: 15 amp 4 ........... F/G/S breaker: 15 amp 5 ........... Spraydown breaker: 15 amp 6 ........... Light breaker: 15 amp 7 ........... Flasher breaker: 15 amp 8 ........... Gate breaker: 30 amp 9 ........... Burner breaker: 50 amp 10 ......... Key switch 11 ......... K2 relay 12 ......... K22 relay

400 & 500 Series Electrical Troubleshooting

13 ......... RH auger/conveyor proportional module 14 ......... LH auger/conveyor proportional module 15 ......... K3 relay 16 ......... K4 relay 17 ......... K5 relay 18 ......... K6 relay 19 ......... K15 relay 20 ......... K16 relay 21 ......... K17 relay 22 ......... K18 relay 23 ......... Spare relay 24 ......... Flasher relay

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22480 (10/01)

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Component Location Map 2nd Generation Version Grayhound 400/500 Series Analog Display 10

9

8

11 12 20 21 30 31

7

6

5

13

16

19

18

14 15 17

22 29

23

24

4 3 2

1

25 26 27

28

36

32

37

33 34

35

28 30 31 29

16

4

1 ............. Travel control 2 ............. Differential lock switch 3 ............. Travel speed pot 4 ............. Rear frame compensator switch 5 ............. Screed assist switch 6 ............. Screed lift switch 7 ............. Screed vibrator switch 8 ............. Engine stop/start/run switch 9 ............. RH conveyor switch 10 ........... LH conveyor switch 11 ........... RH conveyor speed pot 12 ........... LH conveyor speed pot 13 ........... Permissive start switch 14 ........... LH screed extension switch 15 ........... RH screed extension switch 16 ........... Frame raise switch 17 ........... Steer assist switch 18 ........... Flasher switch 400 & 500 Series Electrical Troubleshooting

19 ........... RH flow gate switch 20 ........... LH flow gate switch 21 ........... Hopper wing switch 22 ........... Truck hitch switch 23 ........... Light switch 24 ........... Travel range switch 25 ........... Brake switch 26 ........... Horn switch 27 ........... Throttle switch 28 ........... Audible alarm silence switch 29 ........... Low engine oil pressure indicator light 30 ........... RH mix no flow indicator light 31 ........... LH mix no flow indicator light 32 ........... Oil temperature gauge 33 ........... Voltmeter 34 ........... Fuel level gauge 35 ........... Tachometer 36 ........... Water temperature gauge 37 ........... Oil pressure gauge 11

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A Terex Company

Component Location Map 3rd Generation Version Grayhound 400/500 Series Analog Display

22 21 20 1918 17 16 15 14 13 1 2 3 4 5 6 7 8 9

12

10

11

12 ......... Feed Interface Module 13 ......... K3 relay 14 ......... K4 relay 15 ......... K5 relay 16 ......... K6 relay 17 ......... K15 relay 18 ......... K16 relay 19 ......... K17 relay 20 ......... K18 relay 21 ......... K22 relay 22 ......... Spare relay

1 ........... Engine breaker: 15 amp 2 ........... Screed breaker: 15 amp 3 ........... Control breaker: 15 amp 4 ........... F/G/S breaker: 15 amp 5 ........... Spraydown breaker: 15 amp 6 ........... Light breaker: 15 amp 7 ........... Flasher breaker: 15 amp 8 ........... Gate breaker: 30 amp 9 ........... Burner breaker: 50 amp 10 ......... Key switch 11 ......... K2 relay

400 & 500 Series Electrical Troubleshooting

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Component Location Map 3rd Generation Version Grayhound 400/500 Series Analog Display

10

9

8

7

6

13 20

19

18

21 30 31

22 29

23

5

4 3 2

1

16 14 15 25 26 27

24

28

36 37

32

35

33 34

28 30 31 29

16

4

1 ............. Travel control 2 ............. Steer assist switch 3 ............. Travel speed pot 4 ............. Differential lock switch 5 ............. Screed assist switch 6 ............. Screed lift switch 7 ............. Screed vibrator switch 8 ............. Engine stop/start/run switch 9 ............. RH conveyor switch 10 ........... LH conveyor switch 11 ........... N/A 12 ........... N/A 13 ........... Permissive start switch 14 ........... LH screed extension switch 15 ........... RH screed extension switch 16 ........... Frame raise switch 17 ........... N/A 18 ........... Flasher switch

400 & 500 Series Electrical Troubleshooting

19 ........... RH flow gate switch 20 ........... LH flow gate switch 21 ........... Hopper wing switch 22 ........... Truck hitch switch 23 ........... Light switch 24 ........... Travel range switch 25 ........... Brake switch 26 ........... Horn switch 27 ........... Throttle switch 28 ........... Audible alarm silence switch 29 ........... Low engine oil pressure indicator light 30 ........... RH mix no flow indicator light 31 ........... LH mix no flow indicator light 32 ........... Oil temperature gauge 33 ........... Voltmeter 34 ........... Fuel level gauge 35 ........... Tachometer 36 ........... Water temperature gauge 37 ........... Oil pressure gauge 13

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A Terex Company

Component Location Map Grayhound 400/500 Series Remix Pavers

21 19 18 17 16

K3

20

K4

K5

E

R

K6

A SP

15

13

14

FEED INTERFACE MODULE

1 2 3 4 5 6 7 8 9 10

11

12

12 ......... RH & LH Feed Interface Module 13 ......... Spare Feed Interface Module 14 ......... RH Remix Controller 15 ......... LH Remix Controller 16 ......... K3 relay 17 ......... K4 relay 18 ......... K5 relay 19 ......... K6 relay 20 ......... K22 relay 21 ......... Spare relay

1 ........... Engine breaker: 15 amp 2 ........... Screed breaker: 15 amp 3 ........... Console breaker: 15 amp 4 ........... F/G/S breaker: 15 amp 5 ........... Spraydown breaker: 15 amp 6 ........... Light breaker: 15 amp 7 ........... Flasher breaker: 15 amp 8 ........... Gate breaker: 30 amp 9 ........... Burner breaker: 50 amp 10 ......... Key switch 11 ......... K2 relay

400 & 500 Series Electrical Troubleshooting

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Component Location Map Grayhound 400/500 Series Remix Pavers 10

9

8

7

12

11

13

20

19

18

21

22

23

6

5

4 3 2

1

16 14 15 25 26 27

24

29

36 37

32

35

33 34

32

33

34

35

37 36 29 23

21 22 20 19

26 14 15 24 25 27

18 16

12 11

1

13 4 10

8

7

6

5

3 2

19 ........... RH remix/delivery screw switch 20 ........... LH remix/delivery screw switch 21 ........... Hopper wing switch 22 ........... Truck hitch switch 23 ........... Light switch 24 ........... Travel range switch 25 ........... Brake switch 26 ........... Horn switch 27 ........... Throttle switch 28 ........... Audible alarm silence switch 29 ........... Engine indicator light 30 ........... N/A 31 ........... N/A 32 ........... Oil temperature gauge 33 ........... Voltmeter 34 ........... Fuel level gauge 35 ........... Tachometer 36 ........... Water temperature gauge 37 ........... Oil pressure gauge

1 ............. Travel control 2 ............. Steer assist switch 3 ............. Travel speed pot 4 ............. Differential lock switch 5 ............. Screed assist switch 6 ............. Screed lift switch 7 ............. Screed vibrator switch 8 ............. Engine stop/start/run switch 9 ............. RH spreading auger switch 10 ........... LH spreading auger switch 11 ........... RH remix ratio dial 12 ........... LH remix ratio dial 13 ........... Permissive start switch 14 ........... LH screed extension switch 15 ........... RH screed extension switch 16 ........... Frame raise switch 17 ........... N/A 18 ........... Flasher switch

400 & 500 Series Electrical Troubleshooting

9

15

22480 (10/01)

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A Terex Company

Component Location Map Grayhound 400 & 500 Series

Throttle Solenoid

Alternator Murphy Temp Sensor

Engine Temp Sensor

Engine Oil Pressure Sensor

RPM Pickup

Starter Solenoid

400 & 500 Series Electrical Troubleshooting

K2 Starter Relay

Starter

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Engine Starting System All Grayhound Pavers

ENGINE DOES NOT START Main key switch ON Brake switch ENGAGED Travel switch in NEUTRAL position Control circuit breaker SET Stop/Start switch held in START position Permissive start switch held closed

ENGINE DOES NOT CRANK Check for low battery voltage, loose starter connections or faulty starter. If no voltage 1 to 3 ......... 20 to 3 ........ 21 to 3 ........ 13 to 3 ........ 14 to 3 ........ 16 to 3 ........ 15 to 3 ........ 2 to 3 .........

Defective main key switch. Defective or tripped engine circuit breaker. Defective main key switch. Defective engine start/stop switch. Defective brake switch. Limit switch 3 on LH travel switch defective. (Track) Limit switch 3 on RH travel switch defective. Defective starter relay (K2).

If voltage, check starter motor.

400 & 500 Series Electrical Troubleshooting

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Charging System All Grayhound Pavers

ALTERNATOR NOT CHARGING (12.5 Vdc or less at battery) Main key switch ON Engine running at FULL THROTTLE Voltage should be 13.5 Vdc to 15.5 Vdc from 1 to 3 If no voltage 1 to 3 .......... If no voltage or high voltage (>16 Vdc), defective main key switch or wiring. 20 to 3 ........ If no voltage, defective or tripped engine circuit breaker 21 to 3 ........ If no voltage, defective main key switch 22 to 3 ........ If no voltage, defective engine start/stop switch, loose connection or bad wire. 22 to 3 ........ If no voltage, at terminal of alternator, defective resistor or wiring. If voltage is 12.5 volts or less at alternator (1to 3), repair or replace alternator. If voltage at battery is more than 16 Vdc, check for defective ground connection(s) between battery, frame, engine, and alternator before replacing alternator. BATTERIES Each battery should have about 12.6 Vdc for a total system voltage of 12 to 13 Vdc with engine off. Lower readings than this is indicative of a weak battery and should be serviced.

400 & 500 Series Electrical Troubleshooting

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Throttle & Fuel All Grayhound Pavers

ENGINE RUNS AT IDLE BUT NOT FULL THROTTLE Main key switch ON, engine RUNNING, control circuit breaker SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. Throttle switch to FULL 48 to 3 ........ If no voltage, defective throttle switch. If voltage, defective throttle solenoid or open wiring in solenoid. ENGINE CRANKS BUT DOES NOT START Main key switch ON, brake switch to ENGAGE, hold permissive start switch closed, engine switch to RUN If no voltage: 1 to 3 .......... defective main key switch 20 to 3 ........ defective or tripped engine breaker 21 to 3 ........ defective main key switch 22 to 3 ........ defective engine start switch 23 to 3 ........ broken wire or defective permissive start switch or relay 23 to 3 ........ If voltage defective fuel solenoid ENGINE STOPS WHEN PERMISSIVE START SWITCH IS RELEASED Main key switch ON, brake switch ENGAGED, hold permissive start switch CLOSED After engine starts, the engine light should remain lit until the engine pressure rises above 5 psi and the engine temperature is below 223° F. Release permissive start switch after engine light goes out. 22 to 3 ........ If no voltage and engine dies, defective permissive start relay 400 & 500 Series Electrical Troubleshooting

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Throttle & Fuel All Grayhound Pavers ENGINE LIGHT WILL NOT GO OUT AFTER ENGINE STARTS If continuity across engine water temperature switch, check for overheated engine or defective water temperature switch. If continuity across engine oil pressure switch, check for low engine oil pressure or defective engine oil pressure switch. ENGINE DOES NOT STOP Engine stop/start switch to STOP. 23 to 3 ........ If voltage, defective engine stop/start switch. If no voltage, defective fuel solenoid. ENGINE SHUTS OFF AFTER A PERIOD OF TIME Check the engine oil pressure and water temperature. One of these has exceeded limits and tripped the shutdown system.

400 & 500 Series Electrical Troubleshooting

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Engine Start & Fuel - Elite Engine Grayhound 400/500 Series Rubber Tire Pavers

Track Pavers

ENGINE CRANKS BUT DOES NOT START Main key switch ON, brake switch to ENGAGE, hold permissive start switch closed, engine switch to START If no voltage: 1 to 3 .......... defective main key switch 20 to 3 ........ defective or tripped engine breaker 21 to 3 ........ defective main key switch 22 to 3 ........ defective engine start switch 23A to 3 ..... defective K22 relay 23 to 3 ........ broken wire or defective permissive start switch or relay 23 to 3 ........ If voltage defective fuel solenoid Note: Pull-in coil (wire 23A) has 12VDC only while cranking engine

400 & 500 Series Electrical Troubleshooting

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Horn All Grayhound Pavers

Main Keyswitch 1

12 VDC 3

0 Horn

Power 1

100

19

3

18

3

30 A 100

Horn Relay

Horn Switch

HORN DOES NOT WORK Hold horn switch ON. 1 to 3 .......... If no voltage, defective main key switch. 100 to 3 ...... If no voltage, defective power circuit breaker. If voltage, check: 19 to 3 ........ If voltage, defective horn. If no voltage, check: 100 to 18 ..... If 12 Vdc, replace K3 relay If no voltage, check: 18 to 3 ........ If no voltage, defective K3 relay. If voltage, defective horn switch

400 & 500 Series Electrical Troubleshooting

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A Terex Company

Gauges All Grayhound Pavers

NO GAUGES WORK 20 to 3 ........ If no voltage, check engine circuit breaker 21 to 3 ........ If no voltage, defective main key switch 22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring. INDIVIDUAL GAUGES DO NOT WORK Water temperature: 22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring. 7 to 3 .......... 1500 ohms at 100° F, 125 ohms at 210° F Oil pressure: 22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring. 8 to 3 .......... 0 to 80 ohms at 0 to 80 PSI. Hydraulic temperature: 22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring. 9 to 31 ........ 1500 ohms at 100° F, 125 ohms at 210° F Fuel level: 22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring. 10 to 3 ........ 0 to 90 ohms = empty to full Hourmeter/tachometer: (requires a functional alternator for proper operation) 22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring. 11 to 3 ........ If voltage at tachometer is approximately. 8 Vac with engine running, replace tachometer. 11 to 3 ........ If no voltage at tach., check at alternator, if no voltage, replace alternator. If frequency meter available, frequency should be 250 Hz at idle, 680 Hz at full throttle. 400 & 500 Series Electrical Troubleshooting

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Lights All Grayhound Pavers

FLASHER LIGHTS/STROBE DO NOT WORK Main key switch ON, flasher and engine circuit breaker SET, flasher switch ON engine switch to RUN position. If no voltage: 1 to 3 .......... defective main key switch 20 to 3 ........ defective engine breaker 21 to 3 ........ defective main key switch 22 to 3 ........ defective engine switch 113 to 3 ...... defective flasher switch 113A to 3 ... defective flasher circuit breaker If voltage 113 to 3 and if no voltage 114 to 3, defective flasher relay 111 to 3 ...... If no voltage, defective flasher. If voltage, check for bad light bulb 112 to 3 ...... If no voltage, defective flasher. If voltage, check for bad light bulb LIGHTS DO NOT WORK Main key switch ON, lights and engine circuit breaker SET, light switch ON, engine switch to RUN position. If no voltage: 1 to 3 .......... defective main key switch 20 to 3 ........ defective engine breaker 21 to 3 ........ defective main key switch 22 to 3 ........ defective engine switch 109 to 3 ...... defective light switch 109A to 3 ... defective light circuit breaker If voltage 109 to 3 and no voltage 110 to 3, defective lights relay 110 to 3 ...... If no voltage, defective light switch. If voltage, check for bad light bulb 400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

Technical Manual

A Terex Company

Brakes All Grayhound Pavers

1

1

Main Keyswitch

Control 46 15 A

0

Brake

12 VDC 3

Engage

34

34

Brake Release Sol.

3

'A' Release

BRAKES WILL NOT RELEASE If SWITCH is defective, the brakes WILL remain ENGAGED. Travel speed controllers, vibrators, automatic feed and screed control WILL NOT function. If SOLENOID is defective, the brakes WILL NOT RELEASE. Travel speed controllers, vibrators, automatic feed and screed control WILL function. Check brake solenoid DIN connector for light. If light is ON: (1) Check ground jumper pin 2 to GND pin on DIN connector for loose connection. (2) Defective solenoid coil or hydraulic problem If NO light: 34 to 3 ........ If no voltage is present, switch is defective. If voltage, defective solenoid or DIN connector.

400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

Technical Manual

A Terex Company

Travel Pave (P2) System All Grayhound Pavers

RANGE SWITCH DOES NOT WORK IN TRAVEL Range switch in TRAVEL. Check range solenoid DIN connector for light. If light is ON: Check ground jumper pin 2 to GND pin for loose or bad connection. If connection is good, defective solenoid or hydraulic problem. If NO light: 42 to 3 ........ If no voltage is present, switch is defective. If voltage, defective solenoid or DIN connector.

400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

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A Terex Company

Front Wheel Assist CR451 & CR551 Grayhound Pavers

1

Main Keyswitch

Control 1 46 15 A

12 VDC 3

0

Range

P/4 P/2

27

Fwd Sol.

3

42

Range Sol.

3

Travel

RANGE SWITCH DOES NOT WORK IN TRAVEL Range switch in TRAVEL. Check range solenoid DIN connector for light. If light is ON: Check ground jumper pin 2 to GND pin for loose or bad connection. If connection is good, defective solenoid or hydraulic problem. If NO light: 42 to 3 ........ If no voltage is present, switch is defective. If voltage, defective solenoid or DIN connector. RANGE SWITCH DOES NOT WORK IN P4 (Front wheel assist only) Range switch to P4 (front wheel assist). Check front wheel assist solenoid DIN connector for light. If light is ON: Check ground jumper pin 2 to GND pin for loose or bad connection. If connection is good, defective solenoid or hydraulic problem. If NO light: 27 to 3 ........ If no voltage is present, switch is defective. If voltage, defective solenoid or DIN connector. If DIN connector light is on, defective solenoid.

400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

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A Terex Company

Travel Control CR451 & CR551 Grayhound Pavers Main Keyswitch 1

1

12 VDC 3

0 Control 46 15 A

46

Brake

Engage

34

'A' Release 4 Pin Packard

77 C B D

Travel

A

3 RH A B Reverse Coils 73 3 LH B 3 A 3

34 73 3 74

74

Speed B

Controller

C A

CW

Max Paver Speed 1K½

3 LH D C Forward Coils 78 3 RH D C

3 Pin Packard

TRAVEL SPEED CONTROL DOES NOT WORK (Neither drive wheel moves) Main key switch ON, engine RUNNING, control circuit breaker SET, brakes RELEASED. Carefully actuate the manual override lever on each travel pump. If pumps operate using the manual override levers, proceed with checks. If pumps do not operate, refer to the Hydraulic Troubleshooting section. Without starting engine, main key switch ON, engine start/stop switch to RUN, control circuit breaker SET. 1 to 3 .......... If no voltage, defective Main Key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. Release BRAKES, set the max paver speed dial to MAX and travel lever fully FORWARD. 34 to 3 ........ If no voltage, defective brake switch. 74 to 3 ........ For 411, voltage should be 1.6 Vdc. For 451, voltage should be 2.2 VDC . 78 to 3 ........ For 411, voltage should be 1.6 Vdc. For 451, voltage should be 2.2 VDC. If no voltage, check the S1 limit switch on the travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If the voltage does not decrease to 0.15 Vdc, turn the main key switch off and remove wires 74 and 78 from the console terminal block. Check the resistance of the console cable wiring: 74 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins C and D on the pump. Resistance should be 15 to 25 ohms. 78 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. 400 & 500 Series Electrical Troubleshooting

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A Terex Company

Travel Control CR451 & CR551 Grayhound Pavers Check resistance across pins D and C on the pump. Resistance should be 15 to 25 ohms. Release BRAKES, set the max paver speed dial to MAX and the travel lever fully REVERSE. 34 to 3 ........ If no voltage, defective brake switch. 73 to 3 ........ For 411, voltage should be 1.6 VDC. For 451, voltage should be 2.2 VDC. 77 to 3 ........ For 411, voltage should be 1.6 VDC. For 451, voltage should be 2.2 VDC. If no voltage, check the S1 limit switch on the travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If voltage does not decrease to 0.15 Vdc, turn the main key switch off and remove wires 73 and 77 from the console terminal block. Check the resistance of the console cable wiring: 73 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace EDC if open or shorted. 77 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace EDC if open or shorted CHECKING THE TRAVEL SPEED POT Disconnect the plug to the travel speed pot and check the resistance of the pot. A to B ........ 1000 ±100 ohms at all times A to C ........ Ohms should vary as dial is rotated. B to C ......... Ohms should vary as dial is rotated. PAVER PULLS TO ONE SIDE If paver turns severely to left: Operate manual override on left pump. If left pump operates proceed with electrical checks. If not, refer to hydraulic section. Electrical Checks: Check the resistance of the console cable wiring: 73 to 3 ........ Resistance should be 19.5 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace EDC if open or shorted. Check the resistance of the console cable wiring: 74 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. 400 & 500 Series Electrical Troubleshooting

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Travel Control CR451 & CR551 Grayhound Pavers Check resistance across pins C and D on the pump. Resistance should be 15 to 25 ohms. If paver turns severely to right: Operate manual override on right pump. If right pump operates, proceed with electrical checks. If not refer to hydraulic section. Electrical checks: 77 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace EDC if open or shorted. 78 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump.

400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

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Travel Control & Steer Assist Grayhound Rubber Tire Pavers 1999 & After w/46065-500-34 Module

400 & 500 Series Electrical Troubleshooting

31

22480 (10/01)

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A Terex Company

Travel Control & Steer Assist Grayhound Rubber Tire Pavers 1999 & After w/46065-500-34 Module TRAVEL SPEED CONTROL DOES NOT WORK (Neither drive wheel moves) Main key switch ON, engine RUNNING, control circuit breaker SET, brakes RELEASED. Carefully actuate the manual override lever on each travel pump. If pumps operate using the manual override levers, proceed with checks. If pumps do not operate, refer to the Hydraulic Troubleshooting section. Without starting engine, main key switch ON, engine start/stop switch to RUN, control circuit breaker SET. 1 to 3 .......... If no voltage, defective Main Key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. Release BRAKES, set the max paver speed dial to MAX and travel lever fully FORWARD. 34 to 3 ........ If no voltage, defective brake switch. 74 to 3 ........ For 351, voltage should be 1.6 VDC. For 451/551, voltage should be 2.2 VDC. 78 to 3 ........ For 351, voltage should be 1.6 VDC. For 451/551, voltage should be 2.2 VDC. If no voltage, check the S1 limit switch on the travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If the voltage does not decrease to 0.15 Vdc, turn the main key switch off and remove wires 74 and 78 from the console terminal block. Check the resistance of the console cable wiring: 74 to 3 ........ Resistance should be 15 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins C and D on the pump. Resistance should be 15 to 25 ohms. 78 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins D and C on the pump. Resistance should be 15 to 25 ohms. Release BRAKES, set the max paver speed dial to MAX and the travel lever fully REVERSE. 34 to 3 ........ If no voltage, defective brake switch. 73 to 3 ........ For 351, voltage should be 1.6 VDC. For 451/551, voltage should be 2.2 VDC. 77 to 3 ........ For 351, voltage should be 1.6 VDC. For 451/551, voltage should be 2.2 VDC. If no voltage, check the S1 limit switch on the travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If voltage does not decrease to 0.15 Vdc, turn the main key switch off and remove wires 73 and 77 from the console terminal block. Check the resistance of the console cable wiring: 73 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace EDC if open or shorted. 400 & 500 Series Electrical Troubleshooting

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Travel Control & Steer Assist Grayhound Rubber Tire Pavers 1999 & After w/46065-500-34 Module 77 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace EDC if open or shorted CHECKING THE TRAVEL SPEED POT Disconnect the plug to the travel speed pot and check the resistance of the pot. A to B ........ 1000 ±100 ohms at all times A to C ........ Ohms should vary as dial is rotated. B to C ......... Ohms should vary as dial is rotated. PAVER PULLS TO LEFT OR RIGHT • Move harness plug-in connector from ASSIST position to BYPASS position. This eliminates STEER ASSIST circuitry on Steer Assist Module. If this corrects problem, replace Steer Assist Module. If not, re-check wire connections between console and traction pumps as described above. STEER ASSIST DOES NOT WORK IN P/2 OR P/4 RANGE Steer assist is operational only in P/2 or P/4 Range. Proper operation is indicated when paver pivot turns in the direction that STEER ASSIST switch is held. DIFF. LOCK must also be functional. If DIFF. LOCK is not working, refer to that section first before proceeding. STEER ASSIST DOES NOT WORK IN LEFT POSITION • Range switch in P/2 or P/4 • STEER ASSIST switch held in Left direction • 79 to 3...........If no voltage, replace STEER ASSIST switch. If 12VDC: • 75 to 3...........If no voltage, replace STEER ASSIST switch. If 12VDC: • Check connections at Steer Assist Module, if OK replace Steer Assist Module. STEER ASSIST DOES NOT WORK IN RIGHT POSITION • Range switch in P/2 or P/4 • STEER ASSIST switch held in Right direction • 79 to 3 ..........If no voltage, replace STEER ASSIST switch. If 12VDC: • 76 to 3...........If no voltage, replace STEER ASSIST switch. If 12VDC: • Check connections at Steer Assist Module, if OK replace Steer Assist Module.

400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

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A Terex Company

Travel Control Adjustment Procedure 3 Pot Controller Grayhound Tire Pavers

3 Pot Travel Controller

Low Threshold Reverse Maximum Pot Forward Maximum Pot

CONTROL HANDLE ADJUSTMENT PROCEDURE Initial Adjustment: (Electrical centering) Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running: 1. Turn both MAX adjustment pots on controller fully clockwise. 2. Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust Low Threshold Pot for 0.2 VDC from wire 74 to 3. 3. Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for 2.0 VDC from wire 74 to 3 4. Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0 VDC from wire 73 to 3

400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

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A Terex Company

Travel Control Adjustment Procedure 3 Pot Controller Grayhound Tire Pavers

Operational Adjustment: Note: Center pumps prior to operational adjustments! Wheels off ground; Engine at Full Throttle; Brake switch RELEASED: 1. With Control Handle full forward and MAX PAVER SPEED dial at MIN; wheels should not turn. Adjust Low Threshold Pot so that wheels start to creep at dial setting of '1' to '1.5' but stop at MIN. 2. Turn MAX PAVER SPEED dial to MAX with Control Handle full forward: Check speed of wheel hubs with a tachometer and adjust Max Forward Pot until actual speed is at Maximum. If in doubt, turn pot CCW until speed decreases then back to max speed. 3. Put Control Handle full reverse: Check speed of wheel hubs with a tachometer and adjust Max Reverse Pot. until actual speed is at Maximum. If in doubt, turn pot CCW until speed decreases then back to max speed. 4. Repeat steps 1-3 until adjustment is not necessary. Bias Adjustment Wheels off ground; Engine at Full Throttle; Brake switch RELEASED, balance lines blocked: 1. Control Handle full forward, MAX PAVER SPEED dial at MIN; Slowly increase MAX PAVER SPEED dial until one or both wheels start to turn. 2. If one wheel is not turning carefully adjust neutral of non-turning side pump until both wheels are turning the same speed.

400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

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A Terex Company

Travel Control Adjustment Procedure 3 Pot Controller Grayhound Track Pavers

3 Pot Travel Controller

Low Threshold Reverse Maximum Pot Forward Maximum Pot

LH CONTROL HANDLE ADJUSTMENT PROCEDURE Initial Adjustment: (Electrical centering) Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running: 1. Turn both MAX adjustment pots on controller fully clockwise. 2. Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust Low Threshold Pot for 0.2 VDC from wire 74 to 3. 3. Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for 2.0 VDC from wire 74 to 3 4. Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0 VDC from wire 73 to 3

400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

Technical Manual

A Terex Company

Travel Control Adjustment Procedure 3 Pot Controller Grayhound Track Pavers

3 Pot Travel Controller

Low Threshold Reverse Maximum Pot Forward Maximum Pot

RH CONTROL HANDLE ADJUSTMENT PROCEDURE Initial Adjustment: (Electrical centering) Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running: 1. Turn both MAX adjustment pots on controller fully clockwise. 2. Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust Low Threshold Pot for 0.2 VDC from wire 77 to 3. 3. Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for 2.0 VDC from wire 77 to 3 4. Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0 VDC from wire 78 to 3

400 & 500 Series Electrical Troubleshooting

37

22480 (10/01)

Technical Manual

A Terex Company

Travel Control Adjustment Procedure 3 Pot Controller Grayhound Track Pavers

Operational Adjustment: Note: Center pumps prior to operational adjustments! Engine at Full Throttle; Brake switch RELEASED, hydraulic fluid at operating temperature: 1. With Control Handle full forward and MAX PAVER SPEED dial at MIN; tracks should not move. 2. Adjust Low Threshold Pot so that both tracks start to creep at dial setting of '1' to '1.5' but stop at MIN. 3. Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full forward: Adjust each MAX Forward Pot so that track speeds match (Paver goes straight) and paver is at maximum attainable speed. If in doubt, turn pot CCW until speed decreases then back to max speed. 4. Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full reverse: Adjust each MAX Reverse Pot so that track speeds match (Paver goes straight) and paver is at maximum attainable speed. If in doubt, turn pot CCW until speed decreases then back to max speed. 5. Repeat steps 1-4 until adjustment is not necessary.

400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

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A Terex Company

Travel Control Adjustment Procedure Grayhound Tire Pavers Analog Display w/Lever Control

MINIMUM Forward Pot

MINIMUM Reverse Pot

MAXIMUM Forward Pot

MAXIMUM Reverse Pot

CONTROL HANDLE ADJUSTMENT PROCEDURE Initial Adjustment: (Electrical centering) Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running: . Turn both MAX adjustment pots on controller fully clockwise. . Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust MIN Forward Pot for 0.2 VDC from wire 74 to 3. . Travel lever full REVERSE, MAX PAVER SPEED dial to MIN: Adjust MIN Reverse Pot Clockwise until voltage increases from wire 73 to 3 then turn back. Should be about 0.2 VDC . Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for 2.0 VDC from wire 74 to 3 . Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0 VDC from wire 73 to 3 . While measuring voltage from 73 to 3, turn MAX PAVER SPEED dial slowly down from MAX to MIN with handle in full reverse: Voltage should decrease smoothly down to about 0.2 VDC. If not repeat steps 1-5. . While measuring voltage from 74 to 3, turn MAX PAVER SPEED dial slowly down from MAX to MIN with handle in full forward: Voltage should decrease smoothly down to about 0.2 VDC. If not repeat steps 1-5.

400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

Technical Manual

A Terex Company

Travel Control Adjustment Procedure Grayhound Tire Pavers Analog Display w/Lever Control Operational Adjustment: Note: Center pumps prior to operational adjustments! Wheels off ground; Engine at Full Throttle; Brake switch RELEASED: • With Control Handle full forward and MAX PAVER SPEED dial at MIN; wheels should not turn. Adjust MIN Forward Pot so that wheels start to creep at dial setting of '1' to '1.5' but stop at MIN. • With Control Handle full reverse and MAX PAVER SPEED dial at MIN; wheels should not turn. Adjust MIN Reverse Pot so that wheels start to creep at dial setting of '1' to '1.5' but stop at MIN. • Turn MAX PAVER SPEED dial to MAX with Control Handle full forward: Check speed of wheel hubs with a tachometer and adjust Max Forward Pot until actual speed is at Maximum. If in doubt, turn pot CCW until speed decreases then back to max speed. • Put Control Handle full reverse: Check speed of wheel hubs with a tachometer and adjust Max Reverse Pot. until actual speed is at Maximum. If in doubt, turn pot CCW until speed decreases then back to max speed. • Repeat steps 1-5 until adjustment is not necessary. Bias Adjustment Wheels off ground; Engine at Full Throttle; Brake switch RELEASED, balance lines blocked: 1. Control Handle full forward, MAX PAVER SPEED dial at MIN; Slowly increase MAX PAVER SPEED dial until one or both wheels start to turn. 2. If one wheel is not turning carefully adjust neutral of non-turning side pump until both wheels are turning the same speed.

400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

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A Terex Company

Differential Lock CR451 and CR551 Grayhound Pavers

DIFFERENTIAL LOCK DOES NOT WORK IN P/2 OR P/4 RANGE Differential Lock is operational only in P/2 or P/4 Range. Proper operation is indicated when steering becomes difficult to impossible other than in a straight line. To troubleshoot a suspected problem: • Range switch in P/2 or P/4 • DIFF. LOCK switch held in ON position Check Diff. Lock solenoid DIN connector for light • If light is ON, check for magnetic field with a small screwdriver at the solenoid coil. If no field, check ground jumper from pin 2 to GND pin in DIN connector for tightness. If connection is good, check coil resistance for about 6 ohms. Replace solenoid if bad. If there was a magnetic field, refer to Hydraulic Troubleshooting. • If no light check: • 46A to 3.........If no voltage, replace K20 relay. If 12VDC, check: • 79 to 3............If no voltage, replace DIFF. LOCK switch. If 12VDC: • 79 to Ground at solenoid.....No voltage indicates defective wiring to solenoid. 12VDC at the solenoid without a light indicates either a bad Ground or defective DIN connector. DIFFERENTIAL LOCK FUNCTIONS IN TRAVEL RANGE Differential Lock should NOT work in TRAVEL RANGE. If it is, check: • DIN connector for light. If ON check: • 46A to 3.........If no voltage, check wire 79 for cross short to 12VDC. If 12VDC, check: • 42 to 3 at K20 relay.....If 12VDC, unplug K20 relay. If Diff. Lock solenoid drops out, replace K20 relay. If no voltage, check for defective wiring in console. • If DIN light is OUT, refer to Hydraulic Troubleshooting. 400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

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A Terex Company

Steer Assist CR451 and CR551 Grayhound Pavers

STEER ASSIST DOES NOT WORK IN P/2 OR P/4 RANGE Steer assist is operational only in P/2 or P/4 Range. Proper operation is indicated when paver pivot turns in the direction that STEER ASSIST switch is held. DIFF. LOCK must also be functional. If DIFF. LOCK is not working, refer to that section first before proceeding. STEER ASSIST DOES NOT WORK IN LEFT POSITION • Range switch in P/2 or P/4 • STEER ASSIST switch held in Left direction • 79 to 3 with .If no voltage, replace STEER ASSIST switch. If 12VDC: • 75 to 3...........If no voltage, replace STEER ASSIST switch. If 12VDC: • Is KL relay pulling in? If not, replace or swap with KR relay to check. • If KL relay does pull in, check 74 to 3 in Forward or 73 to 3 in Reverse. Voltage should be 0. If not, replace or swap KL relay with KR relay to check. 400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

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A Terex Company

Steer Assist CR451 and CR551 Grayhound Pavers

STEER ASSIST DOES NOT WORK IN RIGHT POSITION • Range switch in P/2 or P/4 • STEER ASSIST switch held in Right direction • 79 to 3 ..........If no voltage, replace STEER ASSIST switch. If 12VDC: • 76 to 3...........If no voltage, replace STEER ASSIST switch. If 12VDC: • Is KR relay pulling in? If not, replace or swap with KL relay to check. • If KR relay does pull in, check 78 to 3 in Forward or 77 to 3 in Reverse. Voltage should be 0. If not, replace or swap KR relay with KL relay to check. PAVER PULLS TO LEFT WITH STEER ASSIST IN RELEASED (OFF) POSITION • Range switch in P/2 or P/4 • STEER ASSIST switch released • 75 to 3 .........If 12VDC, replace STEER ASSIST switch. If no voltage check: • 74 to 3 in Forward, 73 to 3 in Reverse. If voltage is 0, replace or swap KL relay with KR relay to check. If voltage is identical to 78 to 3 in Forward or 77 to 3 in Reverse, refer to Hydraulic Troubleshooting. PAVER PULLS TO RIGHT WITH STEER ASSIST IN RELEASED (OFF) POSITION • Range switch in P/2 or P/4 • STEER ASSIST switch released • 76 to 3 .........If 12VDC, replace STEER ASSIST switch. If no voltage check: • 78 to 3 in Forward, 77 to 3 in Reverse. If voltage is 0, replace or swap KR relay with KL relay to check. If voltage is identical to 74 to 3 in Forward or 73 to 3 in Reverse, refer to Hydraulic Troubleshooting.

400 & 500 Series Electrical Troubleshooting

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22480 (10/01)

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A Terex Company

LH Travel Speed Control Grayhound CR461 and CR561 Main Keyswitch

1

1

Control 46

46

15 A

12 VDC 0

Brake

3 Engage

34

'A' Release 4 Pin Packard C A D

Left Travel Speed Controller

B B C A

3

Forward Coil 73 3 LH B 3 A 3

74

74

34 73

CW

Max Paver Speed 1K

LH D C Reverse Coil

3

3 Pin Packard Dual Speed Pot

LH TRAVEL SPEED CONTROL DOES NOT WORK Main key switch ON, engine RUNNING, control circuit breaker SET, brakes RELEASED. Carefully actuate the manual override lever on each travel pump. If pumps operate using the manual override levers, proceed with checks. If pumps do not operate, refer to the Hydraulic Troubleshooting section. Without starting the engine, main key switch to ON, engine start/stop switch to RUN, control circuit breaker SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. Release BRAKES. Set the max paver speed dial to MAX and the LH travel lever fully FORWARD. 34 to 3 ........ If no voltage, defective brake switch. 73 to 3 ........ Voltage should be 2.2 Vdc. If no voltage, check the S1 limit switch on the LH travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If the voltage does not decrease to 0.15 Vdc, turn main key switch OFF and remove wire 73 from the console terminal block. Check the resistance of the console cable wiring: 73 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Release BRAKES. Set the max paver speed dial to MAX and the LH travel lever fully REVERSE. 400 & 500 Series Electrical Troubleshooting

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Technical Manual

A Terex Company

LH Travel Speed Control Grayhound CR461 and CR561 34 to 3 ........ If no voltage, defective brake switch. 74 to 3 ........ Voltage should be 2.2 Vdc. If no voltage, check the S1 limit switch on the LH travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If voltage does not decrease to 0.15 Vdc, turn main key switch OFF and remove wire 74 from the console terminal block. Check the resistance of the console cable wiring: 74 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins C and D on the pump. Resistance should be 15 to 25 ohms. CHECKING THE TRAVEL SPEED POT Disconnect the plug to the travel speed pot and check the resistance of the pot. A to B ........ 1000 ±100 ohms at all times A to C ........ Ohms should vary as dial is rotated. B to C ......... Ohms should vary as dial is rotated.

400 & 500 Series Electrical Troubleshooting

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RH Travel Speed Control Grayhound CR461 and CR561

RH TRAVEL SPEED CONTROL DOES NOT WORK Main key switch ON, engine RUNNING, control circuit breaker SET, brakes RELEASED. Carefully actuate the manual override lever on each travel pump. If pumps operate using the manual override levers, proceed with checks. If pumps do not operate, refer to the Hydraulic Troubleshooting section. Without starting engine, main key switch to ON, engine start/stop switch to RUN, control circuit breaker is SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. Release the BRAKES, max paver speed dial to MAX and the RH travel lever fully FORWARD. 34 to 3 ........ If no voltage, defective Brake switch. 77 to 3 ........ Voltage should be 2.2 Vdc. If no voltage, check the S1 limit switch on the RH travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If the voltage does not decrease to 0.15 Vdc, turn main key switch OFF and remove wire 77 from the console terminal block. Check the resistance of the console cable wiring: 77 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. 400 & 500 Series Electrical Troubleshooting

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A Terex Company

RH Travel Speed Control Grayhound CR461 and CR561 Release BRAKES, set max paver speed dial to MAX and the RH travel lever fully REVERSE. 34 to 3 ........ If no voltage, defective brake switch. 78 to 3 ........ Voltage should be 2.2 Vdc. If no voltage, check the S1 limit switch on the RH travel speed controller. If voltage is 12 Vdc, check for an open pump coil or wiring to coil. Set max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc. If voltage does not decrease to 0.15 Vdc, turn main key switch OFF and remove wire 78 from the console terminal block. Check the resistance of the console cable wiring: 78 to 3 ........ Resistance should be 15 to 25 ohms. If wires are open or shorted, disconnect the harness from the appropriate pump. Check resistance across pins C and D on the pump. Resistance should be 15 to 25 ohms. CHECKING THE TRAVEL SPEED POT Disconnect the plug to the travel speed pot and check the resistance of the pot. A to B ........ 1000 ±100 ohms at all times A to C ........ Ohms should vary as dial is rotated. B to C ......... Ohms should vary as dial is rotated.

400 & 500 Series Electrical Troubleshooting

47

22480 (10/01)

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A Terex Company

Travel Control Adjustment Procedure Grayhound Track Pavers Analog Display w/Lever Controls

MINIMUM Forward Pot

MINIMUM Reverse Pot

MAXIMUM Forward Pot

MAXIMUM Reverse Pot

LH CONTROL HANDLE ADJUSTMENT PROCEDURE Initial Adjustment: (Electrical centering) Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running: . Turn both MAX adjustment pots on controller fully counterclockwise. . Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust MIN Forward Pot for 0.2 VDC from wire 73 to 3. . Travel lever full REVERSE, MAX PAVER SPEED dial to MIN: Adjust MIN Reverse Pot Clockwise until voltage increases from wire 74 to 3 then turn back. Should be about 0.2 VDC . Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for 2.0 VDC from wire 73 to 3 . Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0 VDC from wire 74 to 3 . While measuring voltage from 74 to 3, turn MAX PAVER SPEED dial slowly down from MAX to MIN with handle in full reverse: Voltage should decrease smoothly down to about 0.2 VDC If not repeat steps 1-5. . While measuring voltage from 73 to 3, turn MAX PAVER SPEED dial slowly down from MAX to MIN with handle in full forward: Voltage should decrease smoothly down to about 0.2 VDC If not repeat steps 1-5.

400 & 500 Series Electrical Troubleshooting

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A Terex Company

Travel Control Adjustment Procedure Grayhound Track Pavers Analog Display w/Lever Controls

MINIMUM Forward Pot

MINIMUM Reverse Pot

MAXIMUM Forward Pot

MAXIMUM Reverse Pot

RH CONTROL HANDLE ADJUSTMENT PROCEDURE Initial Adjustment: (Electrical centering) Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running: . Turn both MAX adjustment pots on controller fully counterclockwise. . Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust MIN Forward Pot for 0.2 VDC from wire 77 to 3. . Travel lever full REVERSE, MAX PAVER SPEED dial to MIN: Adjust MIN Reverse Pot Clockwise until voltage increases from wire 78 to 3 then turn back. Should be about 0.2 VDC . Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for 2.0 VDC from wire 77 to 3 . Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0 VDC from wire 78 to 3 . While measuring voltage from 78 to 3, turn MAX PAVER SPEED dial slowly down from MAX to MIN with handle in full reverse: Voltage should decrease smoothly down to about 0.2 VDC If not repeat steps 1-5. . While measuring voltage from 77 to 3, turn MAX PAVER SPEED dial slowly down from MAX to MIN with handle in full forward: Voltage should decrease smoothly down to about 0.2 VDC If not repeat steps 1-5.

400 & 500 Series Electrical Troubleshooting

49

22480 (10/01)

Technical Manual

A Terex Company

Travel Control Adjustment Procedure Grayhound Track Pavers Analog Display w/Lever Controls Operational Adjustment: Note: Center pumps prior to operational adjustments! Engine at Full Throttle; Brake switch RELEASED, hydraulic fluid at operating temperature: . With Control Handles full forward and MAX PAVER SPEED dial at MIN, tracks should not move. . Both tracks should start moving at the same speed with a dial setting of '1' to '1.5'. If not, adjust each MIN Forward Pot so that both tracks start to creep at dial setting of '1' to '1.5' but stop at MIN. . With Control Handle full reverse and MAX PAVER SPEED dial at MIN, tracks should not move. . Both tracks should start moving at the same speed with a dial setting of '1' to '1.5'. If not, adjust each MIN Reverse Pot so that both tracks start to creep at dial setting of '1' to '1.5' but stop at MIN. . Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full forward. . Adjust each MAX Forward Pot so that track speeds match (Paver goes straight) and paver is at maximum attainable speed. Maximum attainable speed is when turning the MAX Forward pot CW does not cause paver to turn but turning CCW will cause a turn. . Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full reverse. . Adjust each MAX Reverse Pot so that track speeds match (Paver goes straight) and paver is at maximum attainable speed. Maximum attainable speed is when turning the MAX Reverse pot CW does not cause paver to turn but turning CCW will cause a turn. . Repeat steps 1-8 until adjustment is not necessary.

400 & 500 Series Electrical Troubleshooting

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Susmic 10 Dual Path Control Calibration Procedures Grayhound Track Pavers

Pavers 1999 & Before

Pavers 1999 & After

Scope This document covers the calibration procedures for asphalt pavers equipped with the Sauer-Sunstrand Susmic 10 dual path controller. When to Calibrate These procedures are to be performed after initial vehicle assembly and when a sensor, EDC, pump or motor is replaced. Before beginning these procedures, check to make sure that the Susmic 10 (S10) is properly wired and all inputs are as expected. Table 1 shows all controller inputs and loads and their expected ranges.

400 & 500 Series Electrical Troubleshooting

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Susmic 10 Dual Path Control Calibration Procedures Grayhound Track Pavers Input Forward switch Reverse switch

Wire 351 35 2

Counter rotation

353

Calibrate Brake switch Steer sensor signal Speed pot signal Battery + Battery + Ignition

355 34 332 342 22 22 22

Output Steer sensor power Speed pot power Left forward EDC Left reverse EDC Right forward EDC Right reverse EDC

Wire 331 341 73 74 77 78

Pin Value P1-9 Zero volts in forward P1-27 Zero volts in reverse Zero volts in counter rotate P1-8 (pave mode only) P1-15 Zero volts when calibrate held P1-25 12 volts when brake is released P1-18 1 to 4 volts, left to right P1-19 0.5 to 4.5 volts, min. to max. P1-1 12 volts P1-10 12 volts P1-12 12 volts Pin Value P1-23 5 volts P1-24 5 volts P1-7 0 to 3 volts* P1-20 0 to 3 volts* P1-6 0 to 3 volts* P1-21 0 to 3 volts*

* Depends on Speed Pot Position All Voltage measured made with respect to ground. Ground @ pin P1-2, P1-3, P1-22, P1-13 and EDC Pins B & C. System Function Check A system function check should be performed whenever a component is changed and prior to calibration. Check that all components are installed and that wiring is attached properly. Make sure that all persons are clear of the machine and that space for machine movement exists to the front, rear and both sides. The engine should be at low idle setting and the machine in the work range of operation. 1) Center the steering wheel. Turn the speed set potentiometer to its MINIMUM position. Move the throttle switch to the IDLE position. Move the pave mode switch to the PAVE position. Move the Counter Rotate switch to the NORMAL position. Move the FNR switch to the neutral (N) position. 2) Start the vehicle. The tracks should not move. 3) Move the BRAKE switch to the RELEASE position. The tracks should not move. 4) Slowly turn the SPEED SET potentiometer clockwise. Neither track should move. 400 & 500 Series Electrical Troubleshooting

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Susmic 10 Dual Path Control Calibration Procedures Grayhound Track Pavers 5) Turn the SPEED SET potentiometer to the MINIMUM position. Move the FNR switch to the forward (F) position. The tracks should not move. 6) Slowly turn the SPEED SET potentiometer clockwise. Both tracks should begin to move slowly forward (clockwise). As the SPEED SET pot is increased, the track speed should increase. 7) Slowly turn the STEERING WHEEL to the left. The left track should slow to stop as the wheel is turned. Slowly center the STEERING WHEEL. The left track should speed up to its original rate. 8) Slowly turn the STEERING WHEEL to the right. The right track should slow to stop as the wheel is turned. Slowly center the STEERING WHEEL. The right track should speed up to its original rate. 9) Move the FNR switch to the neutral (N) position. Both tracks should stop. 10) Move the FNR switch to the reverse (R) position. Both tracks should begin turning in reverse. 11) Slowly turn the STEERING WHEEL to the left. The left track should slow to stop as the wheel is turned. Slowly center the STEERING WHEEL. The left track should speed up to its original rate. 12) Slowly turn the STEERING WHEEL to the right. The right track should slow to stop as the wheel is turned. Slowly center the STEERING WHEEL. The right track should speed up to its original rate. 13) Slowly turn the SPEED SET potentiometer counterclockwise towards minimum. Both tracks should slow to a stop by the time the speed pot is at its minimum position. 14) Move the FNR switch to the neutral (N) position. Both tracks should be stopped. If the vehicle performs as described above, the system is prepared for calibration.

400 & 500 Series Electrical Troubleshooting

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Susmic 10 Dual Path Control Calibration Procedures Grayhound Track Pavers CALIBRATION: Calibration procedures are to be performed after initial vehicle assembly and when a sensor, speed set dial, EDC, pump or motor is replaced. Before beginning these procedures, check to make sure that the controller is properly wired and that all test values are as expected. Before beginning calibration, move the vehicle to an open area with 30+ yard run-out. 1) ENGINE switch in STOP. PAVER SPEED dial at minimum. THROTTLE switch in IDLE. RANGE switch in PAVE. COUNTER ROTATE switch in NORMAL. FNR switch in neutral (N). STEERING WHEEL MUST BE CENTERED. 2) Hold the CAL-RUN switch in the CAL position while starting the vehicle. Do not release CAL switch until Engine is brought to FULL THROTTLE. 3) Move the BRAKE switch to the RELEASE position. 4) Turn the STEERING WHEEL all the way to the left and hold. 5) Move the FNR switch to the forward (F) position. Watch the left track closely. As soon as the track begins to move, flip the FNR switch back to neutral (N). 6) Move the FNR switch to the reverse (R) position. Watch the left track closely. As soon as the track begins to move, flip the FNR switch back to neutral (N). 7) Turn the STEERING WHEEL all the way to the right and hold. 8) Move the FNR switch to the forward (F) position. Watch the right track closely. As soon as the track begins to move, flip the FNR switch back to neutral (N). 9) Move the FNR switch to the reverse (R) position. Watch the right track closely. As soon as the track begins to move, flip the FNR switch back to neutral (N). 10) Center the STEERING WHEEL. 11) Move the FNR switch to the forward (F) position. 12) Slowly turn the PAVER SPEED dial to MAXIMUM. Slowly turn PAVER SPEED dial counterclockwise until the vehicle just starts to slow down. Make sure the paver will respond to slight movements of the STEERING WHEEL. Steer paver in a straight path. After 5 seconds without moving the STEERING WHEEL or PAVER SPEED dial, move the FNR switch to the neutral (N) position. 13) Turn the PAVER SPEED dial to MINIMUM. 14) Move the FNR switch to the reverse (R) position. 15) Slowly turn the PAVER SPEED dial to MAXIMUM. Slowly turn PAVER SPEED dial counterclockwise until the vehicle just starts to slow down. Make sure the paver will respond to slight movements of the STEERING WHEEL. Steer paver in a straight path. After 5 seconds without moving the STEERING WHEEL or PAVER SPEED dial, move the FNR switch to the neutral (N) position. 16) Turn the PAVER SPEED dial to MINIMUM. 17) Press and release the CAL-RUN. Move the THROTTLE switch to the IDLE position. Move the BRAKE switch to the ENGAGE position. 18) Wait 5 seconds. 19) Shut off the engine to store values. 400 & 500 Series Electrical Troubleshooting

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Susmic 10 Dual Path Control Calibration Procedures Grayhound Track Pavers Error Checks There are four (4) indicator lights (LED's) located on the side of the track steer controller module located inside of the console; 2 green LED's, 1 yellow and 1 red. Their function is as follows: 1st Green

Power Input

OK if Lit

2nd Green Yellow

Power Output Kernal (Program)

OK if Lit Blinks if functional

Red

Error

Error if lit

On earlier controllers, the red error light would be either ON or OFF, indicating an error. As of software version S0029109 and later, an error code has been assigned to the red LED. The code is a series of short and long flashes consisting of 4 flashes per error with a pause between each error(s). A short flash indicates a "0" and a long flash represents a "1". The following table lists the error codes along with the error associated with it: Error Code 1000* 1100* 1010* 1110* 0100* 0010* 0110* 0001* 1001* 0101* 1101* 0011* 1011 0111 1111

Error Description Steering sensor input is higher than calibrated Steering sensor input is lower than calibrated Steering sensor calibrated too high Steering sensor calibrated too low Speed dial input is higher than calibrated Speed dial input is lower than calibrated Speed dial input is calibrated too high Speed dial input is calibrated too low LH FWD EDC calibration fault RH FWD EDC calibration fault LH REV EDC calibration fault RH REV EDC calibration fault Sensor power fault LH EDC fault RH EDC fault

*Attempt to clear errors by re-calibrating first per complete calibration procedure.

400 & 500 Series Electrical Troubleshooting

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Hopper All Grayhound Pavers

1

Main Keyswitch

0

CONTROL Hopper 46 Wings 1 15 A

12 VDC

3

Raise

65

Raise Sol.

3

Lower

66

Lower Sol.

3

HOPPER WINGS DO NOT RAISE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 65 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. HOPPER WINGS DO NOT LOWER Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 66 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 400 & 500 Series Electrical Troubleshooting

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Truck Hitch (Optional) All Grayhound Pavers Main Keyswitch

1

Control 1

12 VDC

Optional 46 Truck Hitch

15 A

3

0

Engage

61

Engage Sol.

3

Release

62

Release Sol.

3

TRUCK HITCH DOES NOT ENGAGE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 61 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. TRUCK HITCH DOES NOT RELEASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 62 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 400 & 500 Series Electrical Troubleshooting

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Frame Raise All Grayhound Pavers

Main Keyswitch

1

1

Control

0

Rear Frame 46

15 A

12 VDC 3

Raise

70

Raise Sol.

3

Lower

71

Lower Sol.

3

REAR FRAME DOES NOT RAISE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 70 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. REAR FRAME DOES NOT LOWER Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 71 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 400 & 500 Series Electrical Troubleshooting

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LH Flow Gate All Grayhound Pavers Main Keyswitch

1

1

1

12 VDC 3

0

Control 46 15 A Power

LH Gate

30 A

Raise

103

Lower

104

K16

K16

100 100

K15

K15

101 YEL

102 RED 102

K16

3 3

LH Gate Motor 3 3

101 K15

LEFT GATE DOES NOT GO UP Main key switch ON, engine RUNNING, control circuit breaker SET, power circuit breaker SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. LH gate switch to UP. Check for mechanical bind on motor or gate. 100 to 3 ...... If no voltage, defective power circuit breaker. 103 to 3 ...... If no voltage, defective LH gate switch or console cable. 101 to 102 .. If no voltage, defective K15 relay or faulty ground. 101 to 102 .. LH motor leads. If no voltage, there is a break in front harness. If voltage, check for open motor. Motor resistance should be 0.5 ohms. LEFT GATE DOES NOT GO UP Main key switch ON, engine RUNNING, control circuit breaker SET, power circuit breaker SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective Control circuit breaker. LH Gate switch to DOWN. Check for mechanical bind on motor or gate. 100 to 3 ...... If no voltage, defective power circuit breaker. 104 to 3 ...... If no voltage, defective LH gate switch or console cable. 102 to 101 .. If no voltage, defective K16 relay or faulty ground. 102 to 101 .. LH motor leads. If no voltage, there is a break in front harness. If voltage, check for open motor. Motor resistance should be 0.5 ohms.

400 & 500 Series Electrical Troubleshooting

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RH Flow Gate All Grayhound Pavers Main Keyswitch 1

12 VDC 3

0

Control 1

46

RH Gate

15A

Raise

107

Lower

108

Power 1

100

K18 K18

100 30A

K17

K17

105

YEL

106 RED 106

K18

3 3

RH Gate Motor 3 3

105 K17

RIGHT GATE DOES NOT GO UP Main key switch ON, engine RUNNING, control circuit breaker SET, power circuit breaker SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. RH gate switch to UP. Check for mechanical bind on motor or gate. 100 to 3 ...... If no voltage, defective power circuit breaker. 107 to 3 ...... If no voltage, defective RH gate switch or console cable. 105 to 106 .. If no voltage, defective K17 relay or faulty ground. 105 to 106 .. RH motor leads: If no voltage, there is a break in front harness. If voltage, check for open motor. Motor resistance should be 0.5 ohms. RIGHT GATE DOES NOT GO DOWN Main key switch ON, engine RUNNING, control circuit breaker SET, power circuit breaker SET. 1 to 3 .......... If no voltage, defective main keyswitch. 46 to 3 ........ If no voltage, defective control circuit breaker. RH Gate switch to DOWN. Check for mechanical bind on motor or gate. 100 to 3 ...... If no voltage, defective power circuit breaker. 108 to 3 ...... If no voltage, defective RH gate switch or console cable. 106 to 105 .. If no voltage, defective K18 relay or faulty ground. 106 to 105 .. RH motor leads: If no voltage, there is a break in front harness. If voltage, check for open motor. Motor resistance should be 0.5 ohms.

400 & 500 Series Electrical Troubleshooting

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Material Flow Indicators Grayhound Pavers 1999 & Before

Material flow is sensed by switches mounted on the bottom edge of each flow gate. The switches can be manually actuated for testing purposes. Main key switch ON, control circuit breakers SET. Ensure flow switch is clean and moves freely before proceeding. LIGHT AND HORN DO NOT ACTIVATE WHEN MATERIAL IS NOT PRESENT Flow switch in down position (not contacting material) Left Side 88 to 3 ........ If no voltage, defective flow switch 88 to 3 ........ If voltage, defective light bulb 89 to 3 ........ If no voltage, defective diode or loose wire 89A to 3 ..... If no voltage, defective alarm silence relay 89A to 3 ..... If voltage, defective audible alarm Right Side 98 to 3 ........ If no voltage, defective flow switch 98 to 3 ........ If voltage, defective light bulb 89 to 3 ........ If no voltage, defective diode or loose wire 89A to 3 ..... If no voltage, defective alarm silence relay 89A to 3 ..... If voltage, defective audible alarm 400 & 500 Series Electrical Troubleshooting

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Material Flow Indicators Grayhound Pavers 1999 & Before ALARM CANNOT BE SILENCED 89 to 3 ........ (at switch) If no voltage, loose wire Push alarm silence switch 89B to 3 ..... If no voltage, defective alarm silence switch 89B to 3 ..... If voltage, defective alarm silence relay ALARM CAN ONLY BE SILENCED WHILE SWITCH IS HELD CLOSED Release alarm silence switch If alarm continues to sound, defective alarm silence relay or loose wire LIGHT AND HORN ACTIVATE WHEN MATERIAL IS PRESENT The flow switch mounted on the flow gate may stick in the closed position if not cleaned properly as part of daily cleaning procedure. Make sure flow switch is free to move.

400 & 500 Series Electrical Troubleshooting

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Material Flow Indicators Grayhound Pavers 1999 & After

Material flow is sensed by switches mounted on the bottom edge of each flow gate. The switches can be manually actuated for testing purposes. Alarm will not sound unless: At least 1 No Flow Light is ON, Screed in LOWER, Paver moving FORWARD, and Alarm Switch is ON. LIGHT AND HORN DO NOT ACTIVATE WHEN MATERIAL IS NOT PRESENT Flow switch in down position (not contacting material), Brake RELEASED, Travel in FORWARD, Screed Lift in LOWER, and Alarm Switch ON. Left Side 88 to 3 ........ If no voltage, defective flow switch 88 to 3 ........ If voltage, defective light bulb 89 to 3 ........ If no voltage, defective diode or loose wire 89C to 3 ..... If no voltage, defective screed lift switch 89B to 3 ..... If no voltage, defective alarm switch 89A to 3 ..... If no voltage, defective CRFA relay 89A to 3 ..... If voltage, defective alarm Right Side 98 to 3 ........ If no voltage, defective flow switch 98 to 3 ........ If voltage, defective light bulb 89 to 3 ........ If no voltage, defective diode or loose wire 89C to 3 ..... If no voltage, defective screed lift switch 89B to 3 ..... If no voltage, defective alarm switch 89A to 3 ..... If no voltage, defective CRFA relay 89A to 3 ..... If voltage, defective alarm 400 & 500 Series Electrical Troubleshooting

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Material Flow Indicators Grayhound Pavers 1999 & After LIGHT AND HORN ACTIVATE WHEN MATERIAL IS PRESENT The flow switch mounted on the flow gate may stick in the closed position if not cleaned properly as part of daily cleaning procedure. Make sure flow switch is free to move.

400 & 500 Series Electrical Troubleshooting

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Screed Lift All Grayhound Pavers

Main Keyswitch

1

Control 1 46

0

Screed Lift

15 A

12 VDC

Raise

3

63

Raise Sol.

3

64

Lower Sol.

3

Lower

SCREED DOES NOT RAISE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 63 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. SCREED DOES NOT LOWER Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 64 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 400 & 500 Series Electrical Troubleshooting

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A Terex Company

Screed Assist All Grayhound Pavers

SCREED ASSIST WILL NOT COME ON Screed lift switch to LOWER, screed assist switch ON. 46 to 3 ........ If no voltage, defective engine stop/start switch. 64 to 3 ........ If no voltage, defective screed lift switch. 33 to 3 ........ If no voltage, defective screed assist switch. If voltage, check ground wire from solenoid to ground for bad connection. Check for magnetic field with small screwdriver at top of solenoid coil. If no magnetic field, defective screed assist solenoid. If system checks OK using above checks but system is not controlling screed properly, refer to hydraulic troubleshooting or adjustment procedures.

400 & 500 Series Electrical Troubleshooting

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A Terex Company

Power Main Crown All Grayhound Pavers

1

Main Keyswitch

Control 46 1 15 A

Main Crown

12 VDC

3

0

Increase

189

Increase Sol.

3

Decrease

190

Decrease Sol.

3

CROWN DOES NOT INCREASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 189 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. CROWN DOES NOT DECREASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 190 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 400 & 500 Series Electrical Troubleshooting

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Technical Manual

A Terex Company

LH Screed Extend Stretch 20 & Fastach 10 Hydraulic Strike-Off All Grayhound Pavers

CYLINDER DOES NOT EXTEND Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 174 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. CYLINDER DOES NOT RETRACT Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 173 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 400 & 500 Series Electrical Troubleshooting

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Technical Manual

A Terex Company

RH Screed Extend Stretch 20 & Fastach 10 Hydraulic Strike-Off All Grayhound Pavers

CYLINDER DOES NOT EXTEND Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 184 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. CYLINDER DOES NOT RETRACT Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 183 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 400 & 500 Series Electrical Troubleshooting

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Technical Manual

A Terex Company

LH Screed Slope Stretch 20 & Fastach 10 Hydraulic Strike-Off All Grayhound Pavers

SLOPE DOES NOT INCREASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 171 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. SLOPE DOES NOT DECREASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 172 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 400 & 500 Series Electrical Troubleshooting

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Technical Manual

A Terex Company

RH Screed Slope Stretch 20 & Fastach 10 Hydraulic Strike-Off All Grayhound Pavers

SLOPE DOES NOT INCREASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 181 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. SLOPE DOES NOT DECREASE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 182 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 400 & 500 Series Electrical Troubleshooting

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A Terex Company

LH Match Height Stretch 20 All Grayhound Pavers

MATCH HEIGHT DOES NOT RAISE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 175 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. MATCH HEIGHT DOES NOT LOWER Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 176 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 400 & 500 Series Electrical Troubleshooting

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A Terex Company

RH Match Height Stretch 20 All Grayhound Pavers

MATCH HEIGHT DOES NOT RAISE Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 185 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. MATCH HEIGHT DOES NOT LOWER Press Manual Override button on solenoid valve. If not functional, refer to Hydraulic Troubleshooting. If functional, proceed with Electrical checks. Check DIN connector for light. If light is ON: Check for 12 Vdc from pin 1 to pin 2 on DIN connector. If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open. If no voltage, Check ground jumper from pin 2 to GND pin for tightness. If NO light: Check 186 to 3.....If no voltage, replace switch. If voltage, (12 Vdc) check pin 1 of DIN to frame ground. If no voltage, check harness. If voltage, check ground through solenoid to frame for continuity. Correct if necessary. Replace DIN connector if above checks are OK but problem persists. 400 & 500 Series Electrical Troubleshooting

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A Terex Company

Vibrators All Grayhound Pavers Main Keyswitch

12 VDC

1

3

0

Note: Closed in forward (Travel Control) Control 46

1 15 A

Brake

Engage 34 Release

Vibrators Off

47

50

Vibrator Sol.

3

On

Forward L.S.

VIBRATORS WILL NOT COME ON Vibrator switch ON, brakes RELEASED, travel lever(s) FORWARD. Check DIN connector for light. If light is ON: Check pin 2 to GND pin on DIN connector for loose or bad connection. If NO light: 34 to 3 ........ If no voltage, defective brake switch. 47 to 3 ........ If no voltage, defective limit switch(s) on control handle(s). 50 to 3 ........ If no voltage, defective vibrator switch. If voltage but no light, check ground jumper pin 2 to GND pin for loose or bad connection. If good connection, check solenoid coil resistance. It should be approximately 6 ohms. VIBRATORS WILL NOT STOP Vibrator switch OFF. 50 to 3 ....... If voltage present, defective vibrator switch. If no voltage, defective vibrator solenoid valve.

400 & 500 Series Electrical Troubleshooting

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Technical Manual

A Terex Company

LH Main Burner #1 All Grayhound Pavers Main Keyswitch 1

12 VDC 0

3

Fastach Screed Burner Control Burner 1

115 60A 115

Fuel Pump Off On Fan No.1 Off

LH Main Burner (No.1) 116

116

118

Glow Plug No.1 118

On 115

117

117

Fuel Pump Motor 3 Fan Motor No.1

Glow Plug No.1

3

3

NO BURNERS LIGHT If fans work but no burners light, the problem is in the fuel delivery. If fuel pump is running, the problem is in the fuel line. If unsure if fuel pump is running, check the following: Main key switch ON, burner circuit breaker SET, burner fuel valve ON, fuel pump switch ON. 1 to 3 .......... If no voltage, defective main keyswitch 115 to 3 ...... If no voltage, defective burner circuit breaker 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage, check for open motor. If motor is operative, refer to screed system section of instructions to check fuel line. LEFT BURNER DOES NOT LIGHT Main key switch ON, burner circuit breaker SET, burner fuel valve ON, correct glow plug button DEPRESSED. 115 to 3 ...... If no voltage, defective circuit breaker. 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage present but no fuel to burner nozzle, defective fuel pump motor. 118 to 3 ...... If no voltage, defective glow plug push bottom or cable to glow plug. If voltage, but glow plug does not warm, defective glow plug. LEFT BURNER FAN DOES NOT OPERATE 116 to 3 ...... If no voltage, defective fan switch. If voltage, defective fan motor.

400 & 500 Series Electrical Troubleshooting

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A Terex Company

RH Main Burner #2 All Grayhound Pavers Main Keyswitch 1

12 VDC 0

Burner 1

115 60A 115

3

Fuel Pump Off On Fan No.2 Off

Fastach Screed Burner Control

RH Main Burner (No.2) 126

126

128

Glow Plug No.2 128

On 115

117

117

Fuel Pump Motor 3 Fan Motor No.2

Glow Plug No.2

3

3

NO BURNERS LIGHT If fans work but no burners light, the problem is in the fuel delivery. If fuel pump is running, the problem is in the fuel line. If unsure if fuel pump is running, check the following: Main key switch ON, burner circuit breaker SET, burner fuel valve ON, fuel pump switch ON. 1 to 3 .......... If no voltage, defective main keyswitch 115 to 3 ...... If no voltage, defective burner circuit breaker 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage, check for open motor. If motor is operative, refer to screed system section of instructions to check fuel line. RIGHT BURNER DOES NOT LIGHT Main key switch ON, burner circuit breaker SET, burner fuel valve ON, correct glow plug button DEPRESSED. 115 to 3 ...... If no voltage, defective circuit breaker. 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage present but no fuel to burner nozzle, defective fuel pump motor. 128 to 3 ...... If no voltage, defective glow plug push bottom or cable to glow plug. If voltage, but glow plug does not warm, defective glow plug. RIGHT BURNER FAN DOES NOT OPERATE 126 to 3 ...... If no voltage, defective fan switch. If voltage, defective fan motor.

400 & 500 Series Electrical Troubleshooting

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Technical Manual

A Terex Company

LH Ext. Burner #3 All Grayhound Pavers Main Keyswitch 1

12 VDC 0

3

Fastach Screed Burner Control Burner 1

115 60A 115

Fuel Pump Off On Fan No.3 Off

Lt. Ext. Burner (No.3) 136

136

138

Glow Plug No.3 138

On 115

117

117

Fuel Pump Motor 3 Fan Motor No.3

Glow Plug No.3

3

3

NO BURNERS LIGHT If fans work but no burners light, the problem is in the fuel delivery. If fuel pump is running, the problem is in the fuel line. If unsure if fuel pump is running, check the following: Main key switch ON, burner circuit breaker SET, burner fuel valve ON, fuel pump switch ON. 1 to 3 .......... If no voltage, defective main keyswitch 115 to 3 ...... If no voltage, defective burner circuit breaker 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage, check for open motor. If motor is operative, refer to screed system section of instructions to check fuel line. LEFT BURNER DOES NOT LIGHT Main key switch ON, burner circuit breaker SET, burner fuel valve ON, correct glow plug button DEPRESSED. 115 to 3 ...... If no voltage, defective circuit breaker. 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage present but no fuel to burner nozzle, defective fuel pump motor. 138 to 3 ...... If no voltage, defective glow plug push bottom or cable to glow plug. If voltage, but glow plug does not warm, defective glow plug. LEFT BURNER FAN DOES NOT OPERATE 136 to 3 ...... If no voltage, defective fan switch. If voltage, defective fan motor.

400 & 500 Series Electrical Troubleshooting

77

22480 (10/01)

Technical Manual

A Terex Company

RH Ext. Burner #4 All Grayhound Pavers Main Keyswitch 1

12 VDC 0

Burner 1

115 60A 115

3

Fuel Pump Off On Fan No.4 Off

Fastach Screed Burner Control

RH Ext. Burner (No.4) 146

146

148

Glow Plug No.4 148

On 115

117

117

Fuel Pump Motor 3 Fan Motor No.4

Glow Plug No.4

3

3

NO BURNERS LIGHT If fans work but no burners light, the problem is in the fuel delivery. If fuel pump is running, the problem is in the fuel line. If unsure if fuel pump is running, check the following: Main key switch ON, burner circuit breaker SET, burner fuel valve ON, fuel pump switch ON. 1 to 3 .......... If no voltage, defective main keyswitch 115 to 3 ...... If no voltage, defective burner circuit breaker 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage, check for open motor. If motor is operative, refer to screed system section of instructions to check fuel line. RIGHT BURNER DOES NOT LIGHT Main key switch ON, burner circuit breaker SET, burner fuel valve ON, correct glow plug button DEPRESSED. 115 to 3 ...... If no voltage, defective circuit breaker. 117 to 3 ...... If no voltage, defective fuel pump switch. If voltage present but no fuel to burner nozzle, defective fuel pump motor. 148 to 3 ...... If no voltage, defective glow plug push bottom or cable to glow plug. If voltage, but glow plug does not warm, defective glow plug. RIGHT BURNER FAN DOES NOT OPERATE 146 to 3 ...... If no voltage, defective fan switch. If voltage, defective fan motor.

400 & 500 Series Electrical Troubleshooting

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A Terex Company

Rear Frame Compensator Adjustment All Grayhound Pavers

1) Raise or lower frame to about mid range. 2) While holding Comp Switch, adjust pot of Frame Oscillator Module for no net Raise or Lower. • Clockwise rotation on pot will cause frame to raise. • Counter-clockwise rotation on pot will cause frame to lower. • Adjustment must be done between full up and full down on the frame. 3) If properly adjusted, the frame will raise slightly immediate after Comp switch is actuated then stabilize at a "fixed" position.

400 & 500 Series Electrical Troubleshooting

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400 & 500 Series Electrical Troubleshooting

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PAVER TECHNICAL MANUAL

400 & 500 Series Hydraulic Section

Technical Manual A Terex Company

Table of Contents 400 & 500 Series Hydraulic Section Cedarapids Lubricants ......................................................................................................... 1 Pressure Test Kit .................................................................................................................. 2 Component Location Map .............................................................................................. 3 - 8 Throttle ................................................................................................................................ 9 Brake System ..................................................................................................................... 11 Steering ....................................................................................................................... 12 - 13 Truck Hitch (Optional) ............................................................................................... 14 - 15 Hopper Wings ............................................................................................................. 16 - 17 Track Tension - Steel Track Pavers ............................................................................. 18 - 20 Track Tension - Rubber Track Pavers ......................................................................... 21 - 26 Frame Raise - CR451/CR551 ..................................................................................... 28 - 29 Frame Raise - CR461/CR561 ..................................................................................... 30 - 31 Screed Lift - Fastach Screeds ..................................................................................... 32 - 33 Screed Assist - Stretch 20 Screeds .............................................................................. 34 - 35 Tow Point .................................................................................................................... 36 - 37 Main Screed Power Crown ......................................................................................... 38 - 39 Screed Extend - Fastach 10' Screed ............................................................................ 40 - 41 Screed Extend - Stretch 20 Screed.............................................................................. 42 - 43 Sloping Strike-Off: Fastach 10' Screed ...................................................................... 44 - 45 Screed Extension Slope - Stretch 20 Screed ............................................................... 46 - 47 Match Height - Stretch 20 Screed & EZ Screed ......................................................... 48 - 49 Vibrator - Fastach 10' Screed ............................................................................................. 50 Vibrator - Stretch 20 Screed .............................................................................................. 51 Slat Conveyor Feed ............................................................................................................ 52 Remix Spreading Auger..................................................................................................... 53 Remix Delivery Augers .............................................................................................. 54 - 55 Travel/Pave (P2) - Slat Conveyor Pavers ........................................................................... 57 Traction System/Differential Lock - Slat Conveyor Pavers ........................................ 58 - 59 Travel/Pave (P2) - Remix Pavers ....................................................................................... 61 Traction System/Differential Lock - Remix Pavers .................................................... 62 - 63 Front Wheel Assist (Optional) ........................................................................................... 64 4 Kw Hydraulic Drive Generator ...................................................................................... 65 Remote Oil Cooler Driven From Dedicated Pump ........................................................... 66 Remote Oil Cooler Driven From Vibrator Pump .............................................................. 67 400 & 500 Series Hydraulic Troubleshooting

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Technical Manual A Terex Company

Table of Contents 400 & 500 Series Hydraulic Section

400 & 500 Series Hydraulic Troubleshooting

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400 & 500 Series Hydraulic Troubleshooting

1

Greases

Hydraulic Oils

EP Gear Oils

Non-EP Gear Oils

Starfak 2201

Starfak 2202

Multifak EP 2

Starfak 00

Multifak HD 00

Multifak EP 1

Pinnacle 68

Rando HD 68

Pinnacle 32

Rando HD 32

Pinnacle 46

Pinnacle EP 320

Meropa 320

Rando HD 46

Pinnacle EP 220

N/A

Meropa 100

Meropa 220

N/A

Meropa 68

Pinnacle EP 150

Pinnacle 220

Regal R&O 220

Meropa 150

Pinnacle 150

Regal R&O 150

Pinnacle 68

Regal R&O 68

Pinnacle 100

Pinnacle 46

Regal R&O 46

Regal R&O 100

Synthetic

Mineral

Texaco

Alvania EP 2

Alvania EP 1

Alvania EP 00

Tellus 68

Tellus 46

Tellus 32

Omala 320

Omala 220

Omala 150

Omala 100

Omala 68

Molina 220

Molina 150

Molina 100

Turbo T 068

Turbo T 046

Mineral

Synthetic

Albida SLC 220

N/A

Retinax TL 00

Tellus HD 68

Tellus HD 46

Tellus HD 32

Omala HD 320

Omala HD 220

N/A

N/A

N/A

Omala RL 220

Omala RL 150

Omala RL 100

Omala RL 68

Omala RL 46

Shell

Mobilux EP 2

Mobilux EP 1

Mobilux EP 023

DTE 26

DTE 25

DTE 24

Mobilgear 632

Mobilgear 630

Mobilgear 629

Mobilgear 627

Mobilgear 626

Spartan EP 320

Mobilgear SHC 320

Mobilith SHC 220

N/A

Mobilith SHC 007

SHC 526

SHC 525

Lidok EP 2

Lidok EP 1

Lidok EP 000

Nuto H 68

Nuto H 46

Nuto H 32

Spartan EP 220

Mobilgear SHC 220

SHC 524

Spartan EP 150

Spartan EP 100

Spartan EP 68

Teresstic 220

Teresstic 150

Teresstic 100

Teresstic 68

Teresstic 46

Mineral

Dura-Lith EP 2

Dura-Lith EP 1

Ulti-Plex Synthetic EP 1.5

Ulti-Plex Synthetic EP 1.5

N/ A

Rykon Premium Oil 68*

Rykon Premium Oil 46*

Rykon Premium Oil 32*

Tegra Synthetic Gear EP 320

Tegra Synthetic Gear EP 220

Tegra Synthetic Gear EP 150

*A refined mineral oil with properties between mineral and synthetic

Unirex SHP 220

Unirex SHP 460

Dura-Lith EP 00

Hydraulic Oil AW 68

Teresstic SHP 68 Unirex SHP 00

Hydraulic Oil AW 46

Hydraulic Oil AW 32

Teresstic SHP 32 Teresstic SHP 46

Gear Compound EP 320

Gear Compound EP 220 Spartan Synthetic EP 320

Spartan Synthetic EP 220

Gear Compound EP 150

Gear Compound EP 100

Spartan Synthetic EP 100 Spartan Synthetic EP 150

N/A

Gear Compound EP 68 N/A

N/A

N/A

Industrial Oil 220

Teresstic SHP 220

N/A

N/A

Industrial Oil 150

Industrial Oil 100

N/A

N/A

Synthetic

Teresstic SHP 150

Teresstic SHP 100

Industrial Oil 68

Industrial Oil 46

Teresstic SHP 68

Mineral

Teresstic SHP 46

Chevron

Synthetic

Exxon

Mobilgear SHC 150

N/A

N/A

SHC 630

SHC 629

DTE Oil Extra Heavy DTE Oil BB

SHC 627

SHC 626

DTE Oil Heavy Medium DTE Oil Heavy

N/A

Synthetic

DTE Oil Medium

Mineral

Mobil

List of mineral/synthetic interchanges for industrial lubricants used on Cedarapids equipment.

Technical Manual

A Terex Company

Cedarapids Lubricants

22481 (11/01)

Technical Manual

A Terex Company

Pressure Test Kit All Grayhound Pavers

45865-001-41 45865-002-27 45865-002-33

Gauge Gauge Guage

0-6000-PSI 0-100 PSI 0-600 PSI

45080-527-05

Adapter Gauge

Not Illustrated 7430-416 7430-344 7430-345 45080-527-14

45080-527-07 45080-527-15

Hose 36" Hose 10'

45080-527-17 45080-527-18 45080-527-16

45080-527-031 45080-527-061 45080-527-04

400 & 500 Series Hydraulic Troubleshooting

Fitting Tee Tee Test Hose Union

#4 FS JIC Test Port #6 FS JIC Test Port #8 FS JIC Test Port

8" NPT Test Port 4" NPT Test Port #4 SAE Test Port

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A Terex Company

Component Location Map Fastach 10'

L7 L6

L1 L2

L9

L8

L10

L5 L3

L4

L11

L1 ............... L2 ............... L3 ............... L4 ............... L5 ............... L6 ............... L7 ............... L8 ............... L9 ............... L10 ............. L11 .............

400 & 500 Series Hydraulic Troubleshooting

LH screed extend valve LH screed slope valve LH slope cylinder LH extend cylinder Crown solenoid valve Crown motor RH screed extend valve RH screed slope valve RH slope cylinder RH extend cylinder Vibrator motor

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22481 (11/01)

Technical Manual

A Terex Company

Component Location Map Fastach II

3 2

7 4

8

9

6

1 10 5 Cedarapids EXTEND

FEED OVER RIDE

STOP

SLOPE

MATCH

HEIGHT

BERM

TOWPOINT MAN MAN SETUP AUTO HORN

Cedarapids EXTEND

FEED OVER RIDE

STOP

SLOPE E TEMPERATUR RH MAIN

MATCH

RH EXT

HEIGHT LH MAIN LH EXT

CONTROL

HEAT

OUTLET

HEAT

OUTLET

HEAT

HEAT HEAT

BERM

GENERATOR ON

OFF

ON

OFF

TOWPOINT MAN MAN SETUP AUTO HORN

HORN

CROWN E

INCREAS

DECREAS

E

11 12

14

1 ................. 2 ................. 3 ................. 4 ................. 5 ................. 6 ................. 7 ................. 8 ................. 9 .................

13

LH berm valve LH screed extend valve LH match height valve LH screed slope valve LH match height motor RH screed slope valve RH match height valve RH screed extend valve RH berm valve

400 & 500 Series Hydraulic Troubleshooting

10 ............... 11 ............... 12................ 13 ............... 14 ............... Not Shown ............. Not Shown ............. Not Shown ............. Not Shown ............. 4

RH match height motor RH Extension Vibrator Motor RH Main Screed Vibrator motor LH Main Screed Vibrator motor LH Extension Vibrator Motor Crown solenoid valve Crown motor LH slope motor RH slope motor 22481 (11/01)

Technical Manual

A Terex Company

Component Location Map Stretch 20

L14 L12

L16

L13

L17

L15

L19

L20

L18

L21 L23

L22

L24

L24

L24 L12 ............. L13 ............. L14 ............. L15 ............. L16 ............. L17 ............. L18 ............. L19 ............. L20 ............. L21 ............. L22 ............. L23 ............. L24 .............

400 & 500 Series Hydraulic Troubleshooting

LH screed extend valve LH screed slope valve LH match height valve Crown solenoid valve RH match height valve RH screed slope valve RH screed extend valve LH match height motor LH slope motor Crown motor RH match height motor RH slope motor Vibrator motor

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22481 (11/01)

Technical Manual

A Terex Company

Component Location Map Rear Bulkhead

L30 L33

L34

L27 L31

L28

L29 L26 L25

L25 .......... L26 .......... L27 .......... L28 .......... L29 .......... L30 .......... L31 .......... L33 .......... L34 ..........

400 & 500 Series Hydraulic Troubleshooting

LH traction high pressure filter LH conveyor high pressure filter Vibrator solenoid valve Brake solenoid valve Travel/Pave solenoid valve Screed lift solenoid valve Frame raise solenoid valve (rubber) RH traction high pressure filter RH conveyor high pressure filter

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22481 (11/01)

Technical Manual

A Terex Company

Component Location Map Rear Bulkhead (Remix Paver)

8 7

6 11 10 9

4 1 5 3 2

400 & 500 Series Hydraulic Troubleshooting

1 .............. 2 .............. 3 .............. 4 .............. 5 .............. 6 .............. 7 .............. 8 .............. 9 .............. 10 ............ 11 ............

LH spreading auger charge filter LH traction charge filter Delivery auger charge filter Brake solenoid valve Travel/Pave solenoid valve Vibrator solenoid valve Screed lift solenoid valve Frame raise solenoid valve (rubber) RH delivery auger charge filter RH traction high pressure filter RH spreading auger charge filter

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22481 (11/01)

Technical Manual

A Terex Company

Component Location Map Front Bulkhead

L35 L37 L36

L39

L38

L40

L35 ............. L36 ............. L37 ............. L38 ............. L39 ............. L40 ............. L41 .............

Front wheel assist solenoid valve LH pull point solenoid valve Truck hitch solenoid valve LH front wheel assist 5-way valve Hopper solenoid valve RH pull point solenoid valve RH front wheel assist 5-way valve

400 & 500 Series Hydraulic Troubleshooting

8

L41

22481 (11/01)

Technical Manual

A Terex Company

Throttle Grayhound 400 & 500 Series FULL

THROTTLE CYLINDER

IDLE

SOLENOID VALVE

LH CONVEYOR CHARGE PUMP

>> SUCTION >>

10µ FILTER ß2

HYDRAULIC TANK

ENGINE WILL NOT COME TO FULL THROTTLE Engine running Throttle switch to FULL THROTTLE. Check left conveyor to see if it operates. If it does not, refer to conveyor troubleshooting. Watch throttle cylinder. If it extends, refer to engine troubleshooting. Place a small screw driver next to the throttle solenoid. If no magnetic field is felt, refer to electrical. If a magnetic field is felt, throttle switch to IDLE. Remove hose from the rod end of the throttle cylinder. Throttle switch to FULL If oil comes out of the rod end port, blown packing. If no oil comes out rod end port, check flow restrictor for being plugged. If flow restrictor is not plugged, defective solenoid. ENGINE GOES TO FULL THROTTLE WITH SWITCH IN IDLE POSITION Refer to electrical troubleshooting. Check RH conveyor charge pressure. If no pressure refer to conveyor troubleshooting. (Charge pressure is required to hold throttle cylinder in Idle position.)

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

400 & 500 Series Hydraulic Troubleshooting

10

22481 (11/01)

Technical Manual

A Terex Company

Brake System All Grayhound Pavers TO TRACTION PUMP

TORQUE HUB

NOTE: Pressure supplied by common charge pump.

BRAKE ASSEMBLY TO TRACTION PUMP HYDRAULIC MOTOR

COOLER

CHARGE PRESSURE

TANK RANGE & BRAKE LINE TO OTHER TORQUE HUB

BRAKE SYSTEM The brakes are SPRING APPLIED and HYDRAULIC RELEASED. Pressure is supplied by the conveyor or traction charge pump. A brake solenoid valve when energized allows pressure to be applied to the brake piston, allowing the brakes to release. BRAKES WILL NOT RELEASE Engine at FULL THROTTLE. Brake switch to RELEASE. Travel speed dial set above (2). Travel engage/disengage switch to ENGAGE. Check brake solenoid DIN connector for light. If NO light refer to electrical troubleshooting. If light is ON. (1) Refer to electrical for checking ground connection. (2) Install a 600 psi gauge on RH conveyor or traction charge pump (depending on model) high pressure test port. (Do not engage conveyor or traction.) Pressure should be 218 to 265 psi for the brakes to release. If low refer to conveyor or traction system. (3) Install a 600 psi gauge between brake solenoid and brake hose. If no pressure or low, check flow orifice for obstruction or defective solenoid valve. (4) If correct pressure, check brake assembly for warped disks. EMERGENCY BRAKE RELEASE If machine has to be moved and the brakes are locked, refer to instruction decal located on the tool box lid of the paver.

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Steering Grayhound Rubber Tire Pavers

TEST PORT

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage. >> RETURN >>

200 MESH STRAINER

<< CASE DRAIN <<

>> SUCTION >>

PRESSURE FILTER

AUXILIARY SYSTEM HYDRAULIC TANK Check hydraulic fluid level. Engine at FULL THROTTLE. Check other auxiliary functions for operation (screed raise/lower, any extend/ retract function, pull point functions, etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. STEERING WILL NOT TURN LEFT OR RIGHT Engine at FULL THROTTLE. Remove the hose going to the left steering cylinder base end. Install a 3000 psi gauge on the end of the hose. Turn steering wheel to the left, pressure reading should be system pressure. If low or no pressure, defective steering valve. Remove the hose going to the right steering cylinder base end. Install a 3000 psi gauge on the end of the hose. Turn steering wheel to the right, pressure reading should be system pressure. If low or no pressure, defective steering valve. If problem occurs only after cylinders have been fully extended or retracted, check rephase ports Check ball not seating.

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Steering Grayhound Rubber Tire Pavers STEERING WHEELS DRIFT APART It is normal for the wheel to drift apart over a period of time. To get them back in unison, steer against limits in either direction. If the wheels drift apart quickly, preform checks listed above. The cause is usually leaking piston packing on one or both steering cylinders. STEERING CYLINDER TEST With the steering cylinders at mid-stroke, remove the rod end hoses. Cap the rod end ports of the cylinders and plug the hoses. Turn the steering wheel to the left. If the right steering cylinder rod starts to move outward then the packing of the right cylinder may be bad and need to be replaced, or the inner wall of the cylinder tube has a scratch or gouge in it, allowing the hydraulic fluid to go around the packing. Remove the cylinder and replace it. Turn the steering wheel to the right. If the left steering cylinder rod starts to move outward, then the packing of the left steering cylinder may be bad and need to be replaced, or the inner wall of the cylinder tube has a scratch or gouge in it, allowing the hydraulic fluid to go around the packing. Remove the cylinder and replace it. Always remember to flush the hydraulic steering circuit before replacing the hoses onto the cylinders. This is done by coupling the hoses of each cylinder together and turning the steering wheel in one direction for several rotations, and then in the other direction for several rotations.

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Truck Hitch (Optional) All Grayhound Pavers Truck Hitch (Optional)

Pressure Reducing Valve 900 PSI

2050 RPM

.913 CID

Solenoid Valve

200 Mesh Strainer

<<< Case Drain <<<

<<< Return <<<

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

Manifold LH Front

Auxiliary Pump

Test Port

Test Port

2500 PSI

Holding Valve

<<< Pressure <<<

Pressure Filter

AUXILIARY SYSTEM Hydraulic Tank Check hydraulic fluid level. Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, pull point functions and etc.) If other functions work, this indicates the problem in only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to ensure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. TRUCK HITCH WILL NOT EXTEND Engine at FULL THROTTLE. Manual needle valve open (this controls cylinder speed an needs to be open to some extent) Truck hitch switch to the EXTEND position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If truck hitch cylinder extends, defective solenoid. If truck hitch cylinder does not extend: (1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and manifold block. If full pressure reading but no cylinder movement plugged or defective holding valve. (2) Retract cylinder all the way, disconnect the hose going to the BASE END of the cylinders at the manifold. Carefully push the switch to RETRACT. If fluid comes out of the hose going to the base end of the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. 400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Truck Hitch (Optional) All Grayhound Pavers TRUCK HITCH WILL NOT RETRACT Engine at FULL THROTTLE. Truck hitch switch to the RETRACT position. Check for DIN connector light. If no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If truck hitch retracts, defective solenoid. If truck hitch does not retract: (1) Install a 3000 psi gauge in-line, between hose going to base end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Extend cylinder all the way, disconnect the hose going to the ROD END of the truck hitch cylinders at manifold. Carefully push switch to EXTEND. If fluid comes out of the hose going to the truck hitch cylinders, check cylinder for blown piston packing. If no fluid, install a 3000 psi gauge on test port of the truck hitch valve stack. Pressure should be 900 psi. If no pressure, defective solenoid. If low pressure, adjust. TRUCK HITCH DRIFTS OUT Engine at FULL THROTTLE Install a 3000 psi gauge on test port of the truck hitch valve stack. Truck hitch switch to RETRACT. Pressure should be 900 psi at end of stroke. If trucks are not staying aligned in front of the paver they can force oil over relief, causing the hitch to open. If this is not the case proceed with checks. Extend cylinders all the way, disconnect the hose going to the ROD END of the truck hitch cylinders at manifold. Carefully push switch to EXTEND. If fluid comes out of the hose going to the truck hitch cylinders, check cylinder for blown piston packing.

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Hopper Wings All Grayhound Pavers

Hopper Wings

<<< Pressure <<<

Pressure Filter

.913 CID

Solenoid Valve Throttle Valve

Auxiliary Pump

Holding Valve

2050 RPM

2500 PSI

Restrictor

Test Port

200 Mesh Strainer

<<< Case Drain <<<

<<< Return <<<

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

Manifold RH Front

AUXILIARY SYSTEM Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation (screed raise/lower, any extend/ retract function, pull point functions and etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings , damaged hose, or obstructions. HOPPER WINGS WILL NOT RAISE Engine at FULL THROTTLE. Hopper wing switch to the RAISE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If hopper wings raise, defective solenoid. If hopper wings DO NOT raise: (1) Install a 3000 psi gauge in-line, between the hose going to the rod end of the cylinder and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Disconnect the hose going to the base of the hopper cylinders at manifold. Carefully push the hopper switch to RAISE. If fluid comes out of the hose, check cylinders for blown piston packing. 400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Hopper Wings All Grayhound Pavers HOPPER WINGS WILL NOT LOWER Engine at FULL THROTTLE. Hopper wing switch to the LOWER position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If hopper wings lower, defective solenoid. If hopper wings do not lower, carefully crack the hose going to the base of the hopper cylinders. If hopper wings do not start to lower, check for bent or damaged cylinders. If hopper wings lower as fluid is bleed out of the hose, allow to go completely down. (1) Install a 3000 psi gauge in-line between the hose going to the base end of the cylinder and the manifold block. (2) Raise the hopper wings, then try to lower. If full pressure reading, but no cylinder movement, plugged or defective holding valve or plugged flow restrictor.

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Track Tension Steel Track Pavers Tensioning Track

The track is designed to be virtually maintenance free. Proper cleaning and lubrication at the end of each paving day will maintain trouble free operation. However, neglect of the tracks can be expensive. Every time paver is cleaned, the track pins should be sprayed with light oil to lubricate them preventing them from rusting and binding.

If the track looks like it may be getting loose, it can be tested by placing a board or straight edge on the track between the front idler and the first top roller. If the gap between the bottom of the board and the top edge of the track is greater than 3¦4", the track tension must be adjusted. (Figure 2)

The Grayhound track paver uses a tension cylinder mounted above the final drive that maintains a constant volume of pressurized oil to the track adjusting cylinders. When the track encounters an obstacle, the system allows the tensioning idler to recoil rather than stretch or break the track. When the obstacle is cleared the system returns to the previous track tension adjustment.

3/4"

Figure 2 - Checking Track Tension

Important: Perform track tension checks and adjustments when the paver is at running temperature. Adjusting track tension when the paver is cold could lead to over-tensioning of the track.

1 3

Adjust track tension as follows:

4 5 From traction S charge pump

1) Start the engine.

T

2) Open the needle valve slowly to allow the track to retension. (Figure 4)

2

3) Drive the paver forward and backward slowly.

4 - Needle valve 1 - Counterbalance valve 2 - Rodless piston cylinder 5 - Idler tension cylinders 3 - Tensioning cylinder assy.

Warning: Be very careful when reaching over the moving track. Keep feet and loose clothing away from the moving track and rollers.

Figure 1 - Track tension hydraulic circuit

The track tensioning cylinder assembly consists of a cylinder with a rodless piston, a needle valve, and a counterbalance valve. (Figure 1) The piston keeps the oil from the idler tensioning cylinders separated from the main oil supply. When the track encounters an obstacle, it forces oil from the idler cylinders into the bottom side of the rodless cylinder. When the obstruction is cleared, pressurized oil from the traction charge pump forces the tensioning cylinder down which forces idler cylinders to move back to original position.

4) Stop the paver and close needle valve. 5) A properly tensioned track should have a 3¦8" to 1 ¦2" gap between a straightedge and the track. (Figure 3) 3/8" to 1/2"

Figure 3 - Proper Track Tension

The needle valve is used during track tensioning to bring the volume of oil on the bottom side of the rodless cylinder back to the proper level. The counterbalance valve allows oil to flow freely from the top side of the rodless cylinder to the tank when the track encounters an obstacle. 400 & 500 Series Hydraulic Troubleshooting

Warning: Overtightening the track can cause serious damage to the track, idler or drive.

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A Terex Company

Track Tension Steel Track Pavers Track over-pressurizing

8) Turn the engine off and reconnect the hydraulic line to the "T" port.

If the track adjusting system is over-pressurizing during operation, the following procedure must be performed. It is a good idea to perform this check once each season to verify the tensioning cylinder is in good condition.

Track Relief Pressure In addition to adjusting the track tension, the track relief pressure should be checked at least once each season. Check track relief pressure as follows:

Notice: Do not run the paver while the system is over-pressurized. Running with an overpressurized system could damage the track and sprockets.

1) Perform "Track over-pressurizing" procedure above. 2) Stop engine.

T

T

"T" Port

"T" Port Needle Valve

S

Needle Valve

S

Test Port Counter-Balance Valve

Tension Cylinder

Figure 5 - Checking Track Relief Pressure Setting

3) Close needle valve. 4) Bleed off pressure on tension cylinder by installing pressure gauge hose only onto test port and draining fluid into a bucket.

Figure 4 - Bottoming Tension Cylinder

1) Disconnect the line from the "T" port on the track tension cylinder. Install a plug into the disconnected line. (Figure 4)

5) Disconnect the line from the "T" port on the track tension cylinder. Install a plug into the disconnected line. (Figure 5)

2) Attach a drain line to the "T" port and run the other end into a bucket.

6) Install a 3000 PSI gauge on the hose which is connected to the tension cylinder test port.

3) Close the needle valve by rotating clockwise. 4) Start the engine and run at full throttle.

7) Connect a hand operated hydraulic pump to the "T" port on the tension cylinder.

5) If the track was tensioned properly, no oil will flow into the bucket.

8) Start and run engine at full throttle.

6) If only a small amount of oil drains into the bucket, the tension cylinder piston and needle valve are working properly and track will tension properly.

9) Pump the hand pump to apply pressure to the counter balance valve. The counter balance valve will relieve the pressure generated by the pump at the track relief pressure setting. Note the pressure on the gauge when the counter balance valve relieves.

7) If oil continues to flow into the bucket, the tension cylinder piston or needle valve is leaking and must be repaired. 400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Track Tension Steel Track Pavers 10) The track relief pressure setting should be 2050 psi +/- 100 psi. If pressure is outside this range, the counter balance valve requires adjustment. 11) To adjust track relief pressure: a) Loosen jam nut on counter balance valve. b) Rotate the valve counterclockwise to increase the pressure setting. Clockwise rotation will decrease the pressure setting. c) Tighten jam nut. 12) If the pressure can not be set, the counter balance valve is defective and must be replaced. Note - Replacement counter balance valves are factory set and should not require adjustment.

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Track Tension Rubber Track Pavers

Rubber Track Hydraulic System The rubber track hydraulic system maintains a constant volume of pressurized oil to the piston ends of track tension cylinders. Each track is independent and supplied by the auxiliary pump.

When the paver is started, oil is directed from the auxiliary pump to the pressure reducing valves. Oil pressure is reduced from 2500 psi to 1900 psi and directed on to the take-up valves where two separate sections, a charging/isolation cartridge and a direction sensing cartridge, route the oil to the track tension shut-off valves connected to the track tensioning cylinders. A check valve and accumulator for each track are placed between the take-up valve charging/isolation cartridge and the piston side of the track tension shut-off valve. The accumulator is pre-charged with dry nitrogen at 1800 psi to allow the track tensioning cylinders to retract and return if a severe impact is encountered.

REVERSE LH TRACTION DRIVE

LH TRACTION PUMP

FORWARD

AUX

SENSING LINES FROM TRACTION PUMP

SENSING LINES FROM PARKING BRAKES

FROM AUXILIARY PUMP

AUX

SENSING LINES FROM TRACTION PUMP

FORWARD RH TRACTION DRIVE

RH TRACTION PUMP

REVERSE

Figure 6 - Rubber Track Hydraulic System Schematic 400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Track System Components Rubber Track Pavers

Track Tension Shut-off Valve

Take-up Valve

Track Rotated 90˚ for Clarity Pressure Reducing Valves Check Valve

Front

Accumulator

Figure 7 - Rubber Track Hydraulic System Components

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Track Hydraulic System Tests Rubber Track Pavers Checking Rubber Track Hydraulic System The rubber track hydraulic system contains components which will automatically maintain track tension. To check out the system, follow the steps below: Auxiliary System Pump Pressure

Adjusting

First check the auxiliary pump pressure compensator adjustment to be sure the system is set to 2500 +/- 100 psi. See Operation & Maintenance Manual for this procedure.

Screws Pressure Reducing Valves

Pressure Reducing Valves Check the pressure reducing valves on each side (Figure 8).

Test Ports

1) Install pressure gauge (3000 psi) at each test port.

Figure 8 - Pressure Reducing Valves

2) Start and run engine at full throttle. 3) Pressure should read 1900 psi. If not, confirm that the Auxiliary System Pump is putting out 2500 +/- 100 psi as described above. 4) Adjust pressure on reducing valve by loosening jam nut on the valve cartridge, insert an allen wrench into the adjusting screw, and turn the screw clockwise to increase pressure, or counterclockwise to decrease pressure. 5) If 1900 psi still cannot be attained, replace pressure reducing valve.

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Track Hydraulic System Tests Rubber Track Pavers 11) If the pressure is below 1800 psi when it drops quickly to 0 psi, re-charge the accumulator with dry nitrogen as described in Track Tension Accumulator Pre-Charging procedure in the Paver Technical Manual, then test again.

Track Tension Accumulator Check pre-charge of track tension accumulators on each side. 1) Install pressure gauge (3000 psi) at test port marked BTM on the Track Tension Shut-off Valve.

12) If the pressure drops steadily all the way to 0 psi and re-charging the accumulator does not work, then replace the accumulator.

2) Start and run engine at full throttle. 3) Pressure should read 1900 to 2200 psi. 4) Shut engine off. Pressure on gauge should not change.

Direction of Oil Flow

5) Loosen jam nut on shut-off valve cartridge. 6) Insert an allen wrench into the adjusting screw, slowly turn it counter-clockwise to open the shut-off valve and release hydraulic pressure while carefully watching the gauge.

Disconnect & Plug

Accumulator Check Valve

Hose Here

7) The pressure reading should drop off slowly until it reaches the accumulator dry nitrogen precharge pressure. When the pressure reaches the pre-charge point, the gauge will drop quickly to 0 psi.

Figure 9 - Track Tension Accumulator

Track Tension Check Valve and Shut-off Valve

8) The gauge reading at the point where it drops quickly to 0 psi should be 1800 psi at 68 degrees F. This reading may be slightly more or less depending the ambient temperature and the hydraulic system temperature.

Check the operation of the check valve and shut-off valve on each side.

9) If the accumulator dry nitrogen pre-charge is at 1800 psi, then tighten the shut-off valve screw by turning it clockwise until snug on its seat.

2) Start and run engine at full throttle.

10) Re-tighten jam nut on shut-off valve cartridge.

4) Shut off the engine.

1) Install pressure gauge (3000 psi) at test port marked BTM on the shut-off valve.

3) Pressure should read 1900 to 2200 psi.

5) Remove the hose going to the check valve and plug the end of the hose.

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Track Hydraulic System Tests Rubber Track Pavers Caution: Escaping fluid under pressure can penetrate the skin causing serious injury. Be very careful when disconnecting hydraulic or other lines. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. Any fluid injected into the skin must be removed immediately by a doctor.

Track Tensioning Cylinders Check track tensioning cylinders on each side. 1) With engine off, remove lines from shut-off valve to the rod ends of the cylinders. Caution: Escaping fluid under pressure can penetrate the skin causing serious injury. Be very careful when disconnecting hydraulic or other lines. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. Any fluid injected into the skin must be removed immediately by a doctor.

6) Check the gauge reading to see if it drops off. 7) If the gauge reading drops off and oil is leaking from the check valve, replace the check valve. 8) If the gauge reading drops off, no oil is leaking from the check valve and the shut-off valve is closed, replace the shut-off valve.

2) Cap the fittings on the shut-off valves. 3) Start and run engine at full throttle.

9) Re-test as described above until gauge reading does not drop off.

4) With the paver in reverse, brakes released, and the paver moving, there should be no oil leaking from the cylinder rod ports.

10) Re-install the hose to the check valve.

5) If oil is leaking from the cylinder(s) rod ports, the cylinder(s) must be repaired or replaced. BTM Port ROD Port Shut-off Cartridge

Cap Fittings Tensioning Cylinders

Figure 10 - Track Tension Shut-off Valve

Remove Cylinder Rod End Lines Figure 11 - Track Tensioning Cylinders

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

Technical Manual

A Terex Company

Track Hydraulic System Tests Rubber Track Pavers 11) Have another person at the paver console cycle the brake switch on and off several times.

Track Take-up Valve Check track take-up valve on each side. 1) Install pressure gauge (3000 psi) at test ports marked BTM and ROD on the shut-off valve.

12) Each time the brakes are applied, you should be able to feel the hose pulse.

2) Start and run engine at full throttle.

13) If you cannot feel it pulse, remove the accumulator charging cartridge assembly, inspect, clean, and re-install in valve body.

3) With the paver in travel mode, in forward, brakes released, and the paver moving, there should be 1900 psi at the ROD port and 1900 - 2200 psi at the BTM port.

14) Perform the above test once again. 15) If you still cannot feel a pulse in the hose, replace the cartridge assembly in the take-up valve.

Note: To achieve the pressure readings in forward, some resistance/load must be present. Travel up a slight incline if necessary. Slowly increase speed until take-up valve shifts. 4) With the paver in reverse or stopped, brakes released, and on level ground, there should be 1900 psi at the BTM port only. 5) Shut the engine off.

Accumulator Charging Valve Cartridge Assembly

6) With the engine off, the pressure on the BTM port should hold at 1900 psi.

Track Tensioning Valve Cartridge Assembly

7) If the pressure bleeds off, check the shut-off valve as described above. 8) The take-up valve charges the BTM port side of the track tension cylinders each time the brakes are applied. To check this operation: 9) Start and run engine at full throttle. 10) Place your hand on the hose running to the check valve. Figure 12 - Track Take-up Valve

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

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A Terex Company

400 & 500 Series Hydraulic Troubleshooting

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22481 (11/01)

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A Terex Company

Frame Raise Grayhound CR451 and CR551 Pavers Rear Wheel Suspension

<<< Pressure <<<

Pressure Filter

<<< Return <<<

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

Manifold Left Rear

200 Mesh Strainer

Auxiliary Pump

.913 CID

Solenoid Valve

2500 PSI

Holding Valve

2050 RPM

<<< Case Drain <<<

Throttle Valve

Test Port

AUXILIARY SYSTEM Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, pull point functions and etc.) If other functions work, this indicates the problem in only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to ensure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. FRAME WILL NOT RAISE Engine at FULL THROTTLE. Frame raise switch to the RAISE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If frame raises, defective solenoid. If frame does not raise: (1) Install a 3000 psi gauge in-line, between the hose going to the base end of the cylinders and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Extend cylinder all the way, disconnect the hose going to the BASE END of the cylinder. Carefully push the frame switch to RAISE. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. 400 & 500 Series Hydraulic Troubleshooting

28

22481 (11/01)

Technical Manual

A Terex Company

Frame Raise Grayhound CR451 and CR551 Pavers FRAME WILL NOT LOWER Engine at FULL THROTTLE. Frame switch to the LOWER position. Check for DIN connector light. If no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If frame lowers, defective solenoid. If frame does not lower: (1) Install a 3000 psi gauge in-line, between the hose going to the rod end of the cylinder and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Retract cylinder all the way, disconnect the hose going to the ROD END of the frame cylinder. Carefully push the frame switch to lower, If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. FRAME DRIFTS DOWN Engine at FULL THROTTLE Check DIN connectors for lights. If any light on, electrical system is telling the cylinder to move. If no lights are flashing on, proceed with checks. Retract cylinder all the way, disconnect the hose going to the BASE END of the frame cylinders. Carefully push the frame switch to LOWER. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective holding valve. FRAME LOWERS TOO QUICKLY Plugged or defective throttle valve.

400 & 500 Series Hydraulic Troubleshooting

29

22481 (11/01)

Technical Manual

Frame Raise Grayhound CR461 and CR561 Pavers REAR WHEEL SUSPENSION

PRESSURE FILTER

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage.

TEST PORT

2500 RPM

HOLDING VALVE

.913 CID

2500 PSI

THROTTLE VALVE

AUXILIARY PUMP

SOLENOID VALVE MANIFOLD LH REAR

200 MESH STRAINER

AUXILIARY SYSTEM HYDRAULIC TANK Check hydraulic fluid level. Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, pull point functions and etc.) If other functions work, this indicates the problem in only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to ensure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. FRAME WILL NOT RAISE Engine at FULL THROTTLE. Frame raise switch to the RAISE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If frame raises, defective solenoid. If frame does not raise: (1) Install a 3000 psi gauge in-line, between the hose going to the base end of the cylinders and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Retract cylinder all the way, disconnect the hose going to the BASE END of the cylinder. Carefully push the frame switch to RAISE. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. 400 & 500 Series Hydraulic Troubleshooting

30

22481 Rev A (12/04)

Technical Manual

Frame Raise Grayhound CR461 and CR561 Pavers FRAME WILL NOT LOWER Engine at FULL THROTTLE. Frame switch to the LOWER position. Check for DIN connector light. If no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If frame lowers, defective solenoid. If frame does not lower: (1) Install a 3000 psi gauge in-line, between the hose going to the rod end of the cylinder and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Retract cylinder all the way, disconnect the hose going to the ROD END of the frame cylinder. Carefully push the frame switch to lower, If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. FRAME DRIFTS DOWN Engine at FULL THROTTLE Check DIN connectors for lights. If any light on, electrical system is telling the cylinder to move. If no lights are flashing on, proceed with checks. Retract cylinder all the way, disconnect the hose going to the BASE END of the frame cylinders. Carefully push the frame switch to RAISE. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective holding valve. FRAME LOWERS TOO QUICKLY Plugged or defective throttle valve.

400 & 500 Series Hydraulic Troubleshooting

31

22481 Rev A (12/04)

Technical Manual

A Terex Company

Screed Lift All Grayhound Pavers with Fastach Screeds PRESSURE FILTER

2500 RPM

.913 CID

SOLENOID VALVE

AUXILIARY PUMP

HOLDING VALVE

TEST PORT

2500 PSI

RESTRICTOR

<< PRESSURE <<

SCREED LIFT

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage.

200 MESH STRAINER

<
MANIFOLD LH REAR

AUXILIARY SYSTEM Check hydraulic fluid level. HYDRAULIC TANK Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, pull point functions, etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. SCREED LIFT WILL NOT RAISE Engine at FULL THROTTLE. Screed lift switch to the RAISE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If screed lift raises, defective solenoid. If screed lift does not raise: (1) Install a 3000 psi gauge in-line, between the hose going to the rod end of the cylinder and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Disconnect hoses from Base end of the screed lift cylinders. Carefully push the screed lift switch to RAISE. If fluid comes out of the fitting on the cylinders, check cylinder for blown piston packing. 400 & 500 Series Hydraulic Troubleshooting

32

22481 (11/01)

Technical Manual

A Terex Company

Screed Lift All Grayhound Pavers with Fastach Screeds SCREED LIFT WILL NOT LOWER Engine at FULL THROTTLE. Screed lift switch to the LOWER position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If screed lift lowers, defective solenoid. If screed lift does not lower, check for plugged flow restrictor or defective solenoid valve.

400 & 500 Series Hydraulic Troubleshooting

33

22481 (11/01)

Technical Manual

A Terex Company

Screed Assist All Grayhound Pavers with Stretch 20 Screeds 175 PSI Nitrogen Precharge

Screed Lift E

Pressure Filter

Holding Valve I

T Solenoid Valve

2500 RPM

.913 CID

<<< Case Drain <<<

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4-11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

Manifold LH Rear

Auxiliary Pump

Restrictor

Test Port

2500 PSI

D A

<<< Pressure <<<

V

AUXILIARY SYSTEM Hydraulic Tank Check hydraulic fluid level. Engine at FULL THROTTLE. Check other auxiliary functions for operation, (screed raise/lower, any extend/ retract function, tow-point functions, etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions. SCREED LIFT WILL NOT RAISE Engine at FULL THROTTLE. Screed assist switch OFF. Screed lift switch to the RAISE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If screed lift raises, defective solenoid. If screed lift does not raise: (1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Disconnect hoses from base end of the screed lift cylinders. Carefully push the screed lift switch to RAISE. If fluid comes out of the fitting on the cylinders, check cylinder for blown piston packing. 400 & 500 Series Hydraulic Troubleshooting

34

22481 (11/01)

Technical Manual

A Terex Company

Screed Assist All Grayhound Pavers with Stretch 20 Screeds SCREED LIFT WILL NOT LOWER Engine at FULL THROTTLE. Screed assist switch OFF. Screed lift switch to the LOWER position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If screed lift lowers, defective solenoid. If screed lift does not lower, check for plugged flow restrictor or defective solenoid valve. SCREED ASSIST WILL NOT COME ON Engine at FULL THROTTLE. Screed lift switch in LOWER. Screed assist switch ON. Place a small screw driver next to the top of the screed assist solenoid valve. If no magnetic field is felt, refer to electrical troubleshooting. If solenoid attracts screw driver continue with checks: Install a 2000 psi gauge in-line at the ROD end of the screed lift cylinder (either cylinder). Pressure should read same as gauge mounted on bottom of accumulator. If pressure is lower, defective solenoid valve. With gauge in same place, adjust screed assist pressure reducing valve clockwise. The pressure readings should increase. If no increase, defective pressure reducing valve. The working pressure is 200 to 600 psi on the screed assist system. SCREED ASSIST SYSTEM PRESSURE IS NOT STABLE Run checks listed above. Shut machine OFF. OPEN manual dump valve to bleed all pressure from system. Check accumulator for 175 psi pre charge. If no pre-charge remove hose from bottom of accumulator, charge cylinder and listen for blown bladder. REMOVING SCREED ASSIST FROM SYSTEM & CHECKING SCREED LIFT CYLINDERS Shut machine OFF. OPEN manual dump valve to bleed all pressure from system. Disconnect hoses from ports E and V on screed assist manifold. Connect the two hoses together. Plug ports E and V on screed assist manifold to prevent entry of debris. Engine at FULL THROTTLE. Screed lift switch in RAISE position. If screed lowers, defective screed lift cylinder packings.

400 & 500 Series Hydraulic Troubleshooting

35

22481 (11/01)

Technical Manual

A Terex Company

Tow Point All Grayhound Pavers

Pull Point

.913 CID

Solenoid Valve

<<< Return <<<

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

Manifold RH Front

200 Mesh Strainer

Auxiliary Pump

2050 RPM

2500 PSI

Dual Throttle Valve

Test Port

<<< Case Drain <<<

Holding Valve

<<< Pressure <<<

Pressure Filter

AUXILIARY SYSTEM Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point functions and etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for lose fittings, damaged hose, or obstructions. TOW POINT WILL NOT INCREASE Engine at FULL THROTTLE. Tow point increase/decrease switch to the INCREASE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If tow point cylinder increases, defective solenoid. If tow point cylinder does not increase: (1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Extend cylinder all the way, disconnect the hose going to the ROD END of the tow point cylinder. Carefully push the increase/decrease switch to DECREASE. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. 400 & 500 Series Hydraulic Troubleshooting

36

22481 (11/01)

Technical Manual

A Terex Company

Tow Point All Grayhound Pavers TOW POINT WILL NOT DECREASE Engine at FULL THROTTLE. Tow point increase/decrease switch to the DECREASE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If tow point cylinder decreases, defective solenoid. If tow point cylinder does not decrease: (1) Install a 3000 psi gauge in-line, between hose going to base end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Retract cylinder all the way, disconnect the hose going to the BASE END of the tow point cylinder. Carefully push the increase/decrease switch to INCREASE, If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. TOW POINT CYLINDER DRIFTS UP OR DOWN Engine at FULL THROTTLE Check DIN connectors for lights, If any light on, electrical system is telling the cylinder to move. If no lights are flashing on, proceed with checks. Extend cylinder all the way, disconnect the hose going to the ROD END of the tow point cylinder. Carefully push the increase/decrease switch to DECREASE, if fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective holding valve.

400 & 500 Series Hydraulic Troubleshooting

37

22481 (11/01)

Technical Manual

A Terex Company

Main Screed Power Crown All Grayhound Pavers POWER CROWN (OPTIONAL)

P

T

Test Port 2050 RPM

.913 CID P

Auxiliary Pump

B

2500 PSI

A

<<< Pressure <<<

Pressure Filter

200 Mesh Strainer

<<< Case Drain <<<

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4-11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

T

AUXILIARY SYSTEM Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point functions and etc.) If other functions work, this indicates the problem in only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to ensure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose for lose fittings, damaged hose, and obstructions. CROWN WILL NOT INCREASE Engine at FULL THROTTLE. Crown increase/decrease switch to the INCREASE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If crown increases, defective solenoid. If crown does not move, disconnect hose from port B of the manifold valve. Crown switch to INCREASE, if oil comes out of hose and crown does not move, defective motor. If no oil, reconnect hose and install 3000 psi gauge between port A and hose A. Crown switch to INCREASE, if pressure, check for interference on mechanical components or defective motor. 400 & 500 Series Hydraulic Troubleshooting

38

22481 (11/01)

Technical Manual

A Terex Company

Main Screed Power Crown All Grayhound Pavers CROWN WILL NOT DECREASE Engine at FULL THROTTLE. Crown increase/decrease switch to the DECREASE position. Check for DIN connector light, if NO light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If crown increases, defective solenoid. If crown does not move, disconnect hose from port A of the manifold valve. Crown switch to DECREASE, if oil comes out of hose and crown does not move, defective motor. If no oil, reconnect hose and install 3000 psi gauge between port B and hose B. Crown switch to DECREASE. If pressure, check for interference on mechanical components or defective motor.

400 & 500 Series Hydraulic Troubleshooting

39

22481 (11/01)

Technical Manual

A Terex Company

Screed Extend Fastach 10' Screed LH Extend Cylinder

Counterbalance Pressure Filter

<<
Manifold LH Screed

.913 CID

Auxiliary Pump

Throttle

Test Port 2050 RPM

2500 PSI

Solenoid

<<< Case Drain <<<

2000 PSI

>>> Suction >>>

2000 PSI

<<< Pressure <<<

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage.

200 Mesh AUXILIARY SYSTEM Strainer Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point functions and etc.) If other functions work, this indicates the problem in only is the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose for loose fittings, damaged hose or obstructions.

STRIKE-OFF WILL NOT EXTEND Engine at FULL THROTTLE. Strike-off extend/retract switch to the Extend position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If strike-off cylinder extends, defective solenoid. If strike-off cylinder does not extend: (1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Retract cylinder all the way, disconnect the hose going to the BASE END of the strike-off cylinder. Carefully push the extend/retract switch to RETRACT. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. 400 & 500 Series Hydraulic Troubleshooting

40

22481 (11/01)

Technical Manual

A Terex Company

Screed Extend Fastach 10' Screed STRIKE-OFF WILL NOT RETRACT Engine at FULL THROTTLE. Strike-off switch to the Retract position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If strike-off cylinder retracts, defective solenoid. If strike-off cylinder does not retract, (1) Install a 3000 psi gauge in-line, between hose going to base end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Extend cylinder all the way, disconnect the hose going to the ROD END of the strike-off cylinder. Carefully push the extend/retract switch to EXTEND. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. STRIKE-OFF CYLINDER DRIFTS IN OR OUT Engine at FULL THROTTLE Check DIN connectors for lights, If any light ON, electrical system is telling the cylinder to move. If NO lights are flashing, proceed with checks. Extend cylinder all the way, disconnect the hose going to the ROD END of the strike-off cylinder. Carefully push the strike-off switch to EXTEND. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective holding valve.

400 & 500 Series Hydraulic Troubleshooting

41

22481 (11/01)

Technical Manual

A Terex Company

Screed Extend Stretch 20 Screed

<<< Pressure <<<

Pressure Filter

2050 RPM .913 CID

<<< Case Drain <<<

>>> Suction >>>

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage.

<<
Manifold LH Screed

Auxiliary Pump

Solenoid Valve

Test Port

2500 PSI

Holding Valve

200 Mesh Strainer

AUXILIARY SYSTEM Hydraulic Tank Check hydraulic fluid level. Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point functions and etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for lose fittings, damaged hose, or obstructions. SCREED WILL NOT EXTEND Engine at FULL THROTTLE. Screed extend/retract switch to the INCREASE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If screed cylinder extends, defective solenoid. If screed cylinder does not extend: (1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and the manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Retract cylinder all the way, disconnect the hose going to the BASE END of the screed cylinder. Carefully push the increase/decrease switch to RETRACT. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. 400 & 500 Series Hydraulic Troubleshooting

42

22481 (11/01)

Technical Manual

A Terex Company

Screed Extend Stretch 20 Screed SCREED WILL NOT RETRACT Engine at FULL THROTTLE. Screed extend/retract switch to the RETRACT position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection (2) Press MANUAL OVERRIDE button on solenoid valve. If screed cylinder retracts, defective solenoid. If screed cylinder does not retract: (1) Install a 3000 psi gauge in-line, between hose going to base end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Extend cylinder all the way, disconnect the hose going to the ROD END of the screed cylinder. Carefully push the screed switch to extend. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. SCREED CYLINDER DRIFTS IN OR OUT Engine at FULL THROTTLE Check DIN connectors for lights, If any light on, electrical system is telling the cylinder to move. If no lights are flashing on, proceed with checks. Extend cylinder all the way, disconnect the hose going to the ROD END of the screed cylinder. Carefully push the strike-off switch to EXTEND. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective holding valve.

400 & 500 Series Hydraulic Troubleshooting

43

22481 (11/01)

Technical Manual

A Terex Company

Sloping Strike-Off Fastach 10' Screed Slope A

B

B

A

NOTE: EZ Screed II has A & B ports reversed.

Counterbalance

<<< Pressure <<<

Pressure Filter

2050 RPM .913 CID

Auxiliary Pump

Throttle

Test Port

2500 PSI

Solenoid

<<< Case Drain <<<

<<
*Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

Manifold RH Screed

200 Mesh

AUXILIARY SYSTEM Strainer Check hydraulic fluid level. Hydraulic Tank Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point functions, etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings, damaged hose, or obstructions. SLOPE WILL NOT INCREASE Engine at FULL THROTTLE. Slope increase/decrease switch to the INCREASE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If slope cylinder increases, defective solenoid. If slope cylinder does not increase: (1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Decrease cylinder all the way, disconnect the hose going to the BASE END of the slope cylinder. Carefully push the increase/decrease switch to DECREASE. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid. 400 & 500 Series Hydraulic Troubleshooting

44

22481 (11/01)

Technical Manual

A Terex Company

Sloping Strike-Off Fastach 10' Screed SLOPE WILL NOT DECREASE Engine at FULL THROTTLE. Slope increase/decrease switch to the DECREASE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If slope cylinder decreases, defective solenoid. If slope cylinder does not decrease: (1) Install a 3000 psi gauge in-line, between hose going to base end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve. (2) Increase cylinder all the way, disconnect the hose going to the ROD END of the slope cylinder. Carefully push the increase/decrease switch to INCREASE. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid.

400 & 500 Series Hydraulic Troubleshooting

45

22481 (11/01)

Technical Manual

A Terex Company

Screed Extension Slope Stretch 20 Screed

Note: Port "A" on motor is next to ID tag on side of motor.

.913 CID

<<
Manifold RH Screed

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage.

Auxiliary Pump

Single Throttle Valve

2050 RPM 2500 PSI

Solenoid Valve

Test Port

<<< Case Drain <<<

A

>>> Suction >>>

B

Pressure Filter <<< Pressure <<<

Hydraulic Motor

200 Mesh Strainer Hydraulic Tank

AUXILIARY SYSTEM Check hydraulic fluid level. Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point functions and etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings, damaged hose or obstructions. SLOPE WILL NOT INCREASE Engine at FULL THROTTLE. Slope increase/decrease switch to the INCREASE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If slope increases, defective solenoid. If slope does not move, disconnect hose from port B of the manifold valve. Slope switch to INCREASE, if oil comes out of hose and slope does not move, defective motor. If no oil, reconnect hose and install 3000 psi gauge between port A and hose . Slope switch to INCREASE. If pressure, check for interference on mechanical components or defective motor. 400 & 500 Series Hydraulic Troubleshooting

46

22481 (11/01)

Technical Manual

A Terex Company

Screed Extension Slope Stretch 20 Screed SLOPE WILL NOT DECREASE Engine at FULL THROTTLE. Slope increase/decrease switch to the DECREASE position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If slope increases, defective solenoid. If slope does not move, disconnect hose from port A of the manifold valve. Slope switch to DECREASE, if oil comes out of hose and slope does not move, defective motor. If no oil, reconnect hose and install 3000 psi gauge between port B and hose. Slope switch to DECREASE. If pressure, check for interference on mechanical components or defective motor.

400 & 500 Series Hydraulic Troubleshooting

47

22481 (11/01)

Technical Manual

A Terex Company

Match Height Stretch 20 Screed & EZ Screed Hydraulic Motor

Note: "B" port on the motor is next to the name tag on the side of the motor.

Solenoid Valve Single Throttle Valve

Test Port 2050 RPM .913 CID

Auxiliary Pump

A

2500 PSI

B

<<< Pressure <<<

Pressure Filter

<<< Case Drain <<<

*Full Load (RPM): 2100 *Max Flow (GPM): 8.4 - 11.0 Pressure (PSI): 2500 *Varies depending on vintage.

>>> Suction >>>

<<
Hydraulic Motor

200 Mesh Strainer Hydraulic Tank

AUXILIARY SYSTEM Check hydraulic fluid level. Engine at FULL THROTTLE. Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point functions and etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose for loose fittings, damaged hose or obstructions. MATCH HEIGHT WILL NOT RAISE Engine at FULL THROTTLE. Match height up/down switch to the UP position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If match height goes up, defective solenoid. If match height does not move, disconnect hose from port B of the manifold valve. Match height switch to UP, if oil comes out of hose and match height does not move, defective motor. If no oil, reconnect hose and install 3000 psi gauge between port A and hose . Match height switch to UP. If pressure, check for interference on mechanical components or defective motor. 400 & 500 Series Hydraulic Troubleshooting

48

22481 (11/01)

Technical Manual

A Terex Company

Match Height Stretch 20 Screed & EZ Screed MATCH HEIGHT WILL NOT LOWER Match height up/down switch to the DOWN position. Check for DIN connector light, if no light refer to electrical troubleshooting. If light is ON: (1) Refer to electrical for testing ground connection. (2) Press MANUAL OVERRIDE button on solenoid valve. If match height goes up, defective solenoid. If match height does not move, disconnect hose from port A of the manifold valve. Match height switch to DOWN. If oil comes out of hose and match height does not move, defective motor. If no oil, reconnect hose and install 3000 psi gauge between port B and hose . Match height switch to DOWN. If pressure, check for interference on mechanical components or defective motor.

400 & 500 Series Hydraulic Troubleshooting

49

22481 (11/01)

Technical Manual

A Terex Company

Vibrator Fastach 10' Screed

>>>Return>>> Quick Coupling

1500 PSI

<<
>>>Return>>>

Speed Control

>>Suction>>

Vibrators

200 Mesh Strainer Quick Coupling <<
<<
VIBRATORS WILL NOT COME ON Engine at FULL THROTTLE. Brakes RELEASED. Travel engage/disengage to ENGAGE. Speed dial set above 2 Vibrator switch ON. Travel lever FORWARD. Vibrator speed valve turned clockwise all the way. Check vibrator DIN connector for light. If no light refer to electrical. If light is ON: (1) Refer to electrical for testing ground connection. (2) Place a small screw driver next to the solenoid, if no magnetic field is felt refer to electrical. If magnetic field is present, proceed with checks: Turn vibrator shaft by hand, It should turn freely with little resistance. If it can not be turned by hand, check for mechanical failure or bind. Install a 3000 psi gauge in test port. Unplug quick couplings from rear bulk head. Pressure should be 1500 psi. If no pressure, check pump. If low pressure, defective solenoid valve If pressure is correct, reconnect quick couplings. Remove case drain hose from motor and cap hose. If a great amount of oil is coming out of case drain port, the motor is bad. If very little oil comes out of case drain, disconnect return hose from vibrator speed valve and cap hose. If great amount of oil comes out of return port on speed valve, defective speed valve. 400 & 500 Series Hydraulic Troubleshooting

50

22481 (11/01)

Technical Manual

A Terex Company

Vibrator Stretch 20 Screed

>>>Return>>> 1500 PSI <<
Quick Coupling

<<
Speed Control

>>Suction>>

Quick Coupling

LH Front Vibrator

200 Mesh Strainer

RH Front Vibartor

Hydraulic Tank

LH Rear Vibrator

RH Rear Vibartor

VIBRATORS WILL NOT COME ON Engine at FULL THROTTLE. Brakes RELEASED. Vibrator switch ON. Travel lever FORWARD. Vibrator speed valve turned clockwise all the way. Check vibrator DIN connector for light. If no light refer to electrical. If light is ON: (1) Refer to electrical for testing ground connection. (2) Place a small screw driver next to the solenoid, if no magnetic field is felt refer to electrical. If magnetic field is present, proceed with checks: Turn vibrator shafts by hand, They should turn freely with little resistance. If it can not be turned by hand. Check for mechanical failure or bind. If all but one vibrator is turning, check for defective motor on the one that is not turning, install a 3000 psi gauge in test port. Unplug quick couplings from rear bulk head. Pressure should be 1500 psi. If no pressure, check pump. If low pressure, defective solenoid valve If pressure is correct, reconnect quick couplings. Disconnect return hose from vibrator speed valve and cap hose. If great amount of oil comes out of return port on speed valve, defective speed valve. 400 & 500 Series Hydraulic Troubleshooting

51

22481 (11/01)

Technical Manual

A Terex Company

Slat Conveyor Feed Grayhound 400 and 500 Series Charge Filter 5µ ß2

Test Port Charge Pressure Test Port High Pressure 30.3 GPM Max.

9.2 GPM

>>>Pressure>>> 2500 RPM 3800 PSI

220 PSI

2.8 CID .85 CID

Hydraulic Motor 2500 RPM Max. 2.8 CID

>>>Case Drain>>> Cooler <<<Suction<<<

<<
<<
200 Mesh Strainer

CONVEYOR DOES NOT WORK Refer to conveyor electrical troubleshooting checks. Hydraulic Tank Engine at FULL THROTTLE. Push manual override lever in both directions, (one direction will turn the conveyor in forward, the other will turn the conveyor in reverse.) If conveyor does not move in either direction, check pump drive for damaged splines. If drive is ok, install a 600 psi gauge on High pressure test port. Pressure reading will be charge pressure. (Do not engage conveyor) Charge pressure should be 220 psi. If no or low pressure reading, refer to pump service manual. If pressure is ok, install a 6000 psi gauge in the conveyor high pressure test port. Block or chain conveyor to prevent turning. Conveyor switch to manual. Pressure reading should be 3800 psi. If no or low pressure reading, refer to pump service manual. If pressure is OK, check for over loading auger conveyor system (Head of material in auger chamber) chain adjustments or mechanical binds. CONVEYOR STALLS WHEN UNDER LOAD Block or chain conveyor to prevent turning. Engine at FULL THROTTLE. Install a 6000 psi gauge in the high pressure test port. Conveyor switch to MANUAL. Pressure reading should be 3800 psi. If low pressure reading, refer to pump service manual. If pressure is OK, check for over loading auger conveyor system (Head of material in auger chamber) chain adjustments or mechanical binds. 400 & 500 Series Hydraulic Troubleshooting

52

22481 (11/01)

Technical Manual

A Terex Company

Remix Spreading Auger Grayhound 400 and 500 Series Charge Filter Test Port Charge Pressure

5µ ß2

Test Port High Pressure Test Port High Pressure >>>Pressure>>>

Flushing Valve

Hydraulic Motor 2500 RPM Max.

<<
<<<Suction<<< 200 Mesh Strainer

Hydraulic Tank

CONVEYOR DOES NOT WORK Refer to conveyor electrical troubleshooting checks. Engine at FULL THROTTLE. Push manual override lever in both directions, (one direction will turn the auger in forward, the other will turn the auger in reverse.) If auger does not move in either direction, check pump drive for damaged splines. If drive is ok, install a 600 psi gauge on High pressure test port. Pressure reading will be charge pressure. (Do not engage spreading auger) Charge pressure should be 205 psi. If no or low pressure reading, refer to pump service manual. If pressure is ok, install a 6000 psi gauge in the high pressure test port. Disconnect the hose from the pressure side of the hydraulic motor. Cap and plug the end of the hose and port in the motor. This will prevent fluid flow to allow high pressure setting to be checked. Feed conveyor switch to override. Pressure reading should be 3330 psi. If no or low pressure reading, refer to pump service manual. If pressure is OK, check for overloaded spreading auger system. CONVEYOR STALLS WHEN UNDER LOAD Disconnect the hose from the pressure side of the hydraulic motor. Cap and plug the end of the hose and port in the motor. This will prevent fluid flow to allow high pressure setting to be checked. Engine at FULL THROTTLE. Install a 6000 psi gauge in the high pressure test port. Feed conveyor switch to override. Pressure reading should be 3330 psi. If low pressure reading, refer to pump service manual. If pressure is OK, check for over loaded spreading auger system. 400 & 500 Series Hydraulic Troubleshooting

53

22481 (11/01)

Technical Manual

Remix Delivery Augers Grayhound 400 and 500 SeriesRemix

DELIVERY AUGERS DO NOT WORK Refer to conveyor electrical troubleshooting checks. Engine at FULL THROTTLE. Push manual override lever on pump EDC in both directions, (one direction will turn the conveyor in forward, the other will turn the conveyor in reverse.) If conveyor does not move in either direction, check pump drive for damaged splines. If drive is ok, install a 600 psi gauge on High pressure test port. Pressure reading will be charge pressure. (Do not engage conveyor) Charge pressure should be 390 psi. If no or low pressure reading, refer to pump service manual. If pressure is ok, install a 10,000 psi gauge in the conveyor high pressure test port. Disconnect the hose from the pressure side of the hydraulic motor. Cap and plug the end of the hose and port in the motor. This will prevent fluid flow to allow high pressure setting to be checked. Remix conveyor switch to ON. Pressure reading should be 6000 psi. If no or low pressure reading, refer to pump service manual. If pressure is OK, check for over loading auger conveyor system (Head of material in auger chamber) or mechanical binds. DELIVERY AUGER STALLS WHEN UNDER LOAD Disconnect the hose from the pressure side of the hydraulic motor. Cap and plug the end of the hose and port in the motor. This will prevent fluid flow to allow high pressure setting to be checked. Engine at FULL THROTTLE. Install a 10,000 psi gauge in the high pressure test port. Remix conveyor switch to ON. Pressure reading should be 6000 psi. If low pressure reading, refer to pump service manual. If pressure is OK, check for over loading auger conveyor system (Head of material in auger chamber) or mechanical binds. 400 & 500 Series Hydraulic Troubleshooting

54

22481 RevA (12/04)

Technical Manual

A Terex Company

Remix Delivery Augers Grayhound 400 and 500 Series

This Page Intentionally Left Blank

400 & 500 Series Hydraulic Troubleshooting

55

22481 (11/01)

Technical Manual

A Terex Company

Remix Delivery Augers Grayhound 400 and 500 Series

This Page Intentionally Left Blank

400 & 500 Series Hydraulic Troubleshooting

56

22481 (11/01)

Technical Manual

A Terex Company

Travel/Pave (P2) Grayhound Slat Conveyor Pavers Pressure limiter hose (rubber tire only)

Range Shift

Pressure Filter Traction Pump

Strainer

Hydraulic Tank

Motor and Torque Hub Rubber Tire Only

TRAVEL/PAVE (P2) SPEED SELECT All Grayhound pavers have variable displacement traction drive motors. If the range shift solenoid is energized pressure is applied to each Hydraulic Displacement control, causing the motor to turn faster at the same pump output. Rubber tired paver with the Front Wheel Assist option are marked Travel, P2, P4. The systems are the same, for Travel and P/2 In P4 a front wheel assist system is used. Refer to Front Wheel Assist for questions concerning it. PAVER WILL NOT SHIFT TO TRAVEL Engine at FULL THROTTLE. Brakes released. Travel/Pave (Travel/P2/P4) switch to TRAVEL. Check range shift solenoid DIN connector for light. If NO light , refer to electrical troubleshooting. If light is ON: (1) Refer to electrical troubleshooting for ground connection. (2) Install a 600 psi gauge on the RH (traction or conveyor depending on model) high pressure test port. (Do not engage conveyor or travel.) (3) Pressure should be 265 psi to change the hydraulic displacement controls on the motors. If low, refer to conveyor or traction depending on model. (4) Install a 600 psi gauge between the range shift solenoid and the hose going to the motors. If no pressure or low, check flow restricter for obstruction or defective solenoid. If pressure is correct, refer to hydraulic motor manual of your model of paver. 400 & 500 Series Hydraulic Troubleshooting

57

22481 (11/01)

Technical Manual

A Terex Company

Traction System/Differential Lock Grayhound Slat Conveyor Pavers

Differental Lock

LH Traction Drive Parking Brake

To RH Traction System (Rubber Tire Only)

Charge Pressure LH Traction Pump

Range Shift

390 PSI 2500 RPM 2.8 1.4 CID CID

200 Mesh Strainer Hydraulic Tank

TRACTION SYSTEM WILL NOT WORK (Refer to traction electrical troubleshooting.) TRACTION SYSTEM TOWS TO ONE SIDE ONLY Refer to traction electrical troubleshooting. Disconnect and cap cross over lines and ports between LH & RH FORWARD & REVERSE high pressure ports. Install 600 psi gauges in FORWARD & REVERSE high pressure test ports, on side that is not towing. Engine at FULL THROTTLE. Pressure should be 350 psi and within 40 psi of each other. If low refer to pump service manual. If charge pressure cannot be adjusted, disconnect case drain hose and check for oil flow from motor. If oil is flowing out of motor, disconnect high pressure hoses (forward & reverse) to motor & cap. Recheck charge pressure. If pressure is ok, refer to motor service manual. If pressure still low, refer to pump service manual. If pressure greater than 40 psi of each other, refer to pump service manual for pump centering. Install 6000 psi gauges in the FORWARD & REVERSE high pressure test ports. Unplug Brake DIN connector from brake solenoid valve. (this will lock up the brakes) Brake switch to OFF. Travel speed pot to 10. Engine at FULL THROTTLE. Travel lever or lever on slow side, FORWARD. Then lever to REVERSE. Pressure should be 5400 psi. If low refer to pump service manual. Push manual override in each direction. Pressure should be 5400 psi. If low refer to pump service manual. 400 & 500 Series Hydraulic Troubleshooting

58

22481 (11/01)

Technical Manual

A Terex Company

Traction System/Differential Lock Grayhound Slat Conveyor Pavers DIFFERENTIAL LOCK DOES NOT FUNCTION Check DIN connector light If no light, refer to electrical troubleshooting If light is on (1) refer to electrical troubleshooting for ground connection. (2) If valve has a good ground and differential lock does not function, replace valve. RUBBER TIRE TRACTION HYDRAULIC SYSTEM Balance lines should be capped when troubleshooting rubber tire paver traction hydraulic system. This will prevent fluid from flowing between the left and right pump during testing. If the differential lock valve is functioning properly you only need to engage the Differential Lock Switch. But to ensure that there is no chance of fluid passing between the left side pump and the right side pump you need to plug the hoses and cap the ports of one side of the valve. Left Side Traction System Pressure Port 'B'

Left Side Traction System Pressure Port 'A'

Plug Differential Lock Valve

Cap

Cap Plug

Right Side Traction System Pressure Port 'A'

Right Side Traction System Pressure Port 'B'

400 & 500 Series Hydraulic Troubleshooting

59

22481 (11/01)

Technical Manual

A Terex Company

Remix Delivery Augers Grayhound 400 and 500 Series

This Page Intentionally Left Blank

400 & 500 Series Hydraulic Troubleshooting

60

22481 (11/01)

Technical Manual

A Terex Company

Travel/Pave (P2) Grayhound Remix Pavers

TRAVEL/PAVE (P2) SPEED SELECT All Grayhound pavers have variable displacement traction drive motors. If the range shift solenoid is energized pressure is applied to each Hydraulic Displacement control, causing the motor to turn faster at the same pump output. Rubber tired paver with the Front Wheel Assist option are marked Travel, P2, P4. The systems are the same, for Travel and P/2 In P4 a front wheel assist system is used. Refer to Front Wheel Assist for questions concerning it. PAVER WILL NOT SHIFT TO TRAVEL Engine at FULL THROTTLE. Brakes released. Travel/Pave (Travel/P2/P4) switch to TRAVEL. Check range shift solenoid DIN connector for light. If NO light , refer to electrical troubleshooting. If light is ON: (1) Refer to electrical troubleshooting for ground connection. (2) Install a 600 psi gauge on the RH (traction or conveyor depending on model) high pressure test port. (Do not engage conveyor or travel.) (3) Pressure should be 295 psi to change the hydraulic displacement controls on the motors. If low, refer to conveyor or traction depending on model. (4) Install a 600 psi gauge between the range shift solenoid and the hose going to the motors. If no pressure or low, check flow restricter for obstruction or defective solenoid. If pressure is correct, refer to hydraulic motor manual of your model of paver. 400 & 500 Series Hydraulic Troubleshooting

61

22481 (11/01)

Technical Manual

A Terex Company

Traction System/Differential Lock Grayhound Remix Pavers TO RH TRACTION SYSTEM

TRACTION SYSTEM WILL NOT WORK (Refer to traction electrical troubleshooting.) TRACTION SYSTEM TOWS TO ONE SIDE ONLY Refer to traction electrical troubleshooting. Disconnect and cap cross over lines and ports between LH & RH FORWARD & REVERSE high pressure ports. Install 600 psi gauges in FORWARD & REVERSE high pressure test ports, on side that is not towing. Engine at FULL THROTTLE. Pressure should be 295 psi and within 40 psi of each other. If low refer to pump service manual. If charge pressure cannot be adjusted, disconnect case drain hose and check for oil flow from motor. If oil is flowing out of motor, disconnect high pressure hoses (forward & reverse) to motor & cap. Recheck charge pressure. If pressure is ok, refer to motor service manual. If pressure still low, refer to pump service manual. If pressure greater than 40 psi of each other, refer to pump service manual for pump centering. Install 6000 psi gauges in the FORWARD & REVERSE high pressure test ports. Unplug Brake DIN connector from brake solenoid valve. (this will lock up the brakes) Brake switch to OFF. Travel speed pot to 10. Engine at FULL THROTTLE. Travel lever or lever on slow side, FORWARD. Then lever to REVERSE. Pressure should be 5550 psi. If low refer to pump service manual. Push manual override in each direction. Pressure should be 5550 psi. If low refer to pump service manual. 400 & 500 Series Hydraulic Troubleshooting

62

22481 (11/01)

Technical Manual

A Terex Company

Traction System/Differential Lock Grayhound Remix Pavers DIFFERENTIAL LOCK DOES NOT FUNCTION Check DIN connector light If no light, refer to electrical troubleshooting If light is on (1) refer to electrical troubleshooting for ground connection. (2) If valve has a good ground and differential lock does not function, replace valve.

400 & 500 Series Hydraulic Troubleshooting

63

22481 (11/01)

Technical Manual

A Terex Company

Front Wheel Assist (Optional) All Grayhound Rubber Tire Pavers

FROM TRACTION PUMP DRIVE MOTOR

>>CASE DRAIN>>

FRONT WHEEL ASSIST 4WD PILOT VALVE

FROM TRACTION PUMP

DRIVE MOTOR

>> CASE DRAIN >>

FRONT WHEEL ASSIST (P4) The front wheel assist system should not be confused with or considered as a four wheel drive system. When the front wheel assist solenoid valve is energized pressure is applied to separate 5 way valves. When the 5-way valves are open, pressure from the main traction pump is applied to both the main drive motor and the front wheel assist motor on that side of the machine. The amount of tractive effort increase will depend on the amount of traction the front wheels have in a given ground condition. FRONT WHEEL ASSIST WILL NOT ENGAGE Engine at FULL THROTTLE. Travel/P2/P4 switch to P4. Check front wheel assist solenoid valve DIN connector for light. If NO light, refer to electrical troubleshooting. If light is ON, (1) Refer to electrical troubleshooting for ground connection (2) Install a 600 psi gauge in the LH conveyor high pressure test port. (Do Not engage conveyor) Refer to conveyor charge pressure above for pressure required. If pressure is low, refer to conveyor. (3) If pressure is correct, install 600 psi gauge between A port and hose going to the 5 way valves. If no or low pressure, defective solenoid valve. (4) If pressure is correct, install 6000 psi gage between 5-way valve and motor. Move machine. If very low or no pressure, defective 5-way valve on that side. Both sides will need to be checked. 400 & 500 Series Hydraulic Troubleshooting

64

22481 (11/01)

Technical Manual

A Terex Company

4 Kw Hydraulic Drive Generator 400 & 500 Series Grayhound Pavers From screed vibrators 1500 PSI

Solenoid RH Reservoir CF RH Reservoir 3600 RPM

To screed vibrators

EF

Gen Set .38 Motor CID

Flow Control Valve RH Reservoir 17 GPM

IN Priority Flow Divider

2300 PSI RH Reservoir

1.53 CID

2500 RPM

GENERATOR DOES NOT PRODUCE ELECTRICITY RH Reservoir Engine at full throttle, generator switch to ON. Check for light on solenoid DIN connector. If no light, refer to electrical troubleshooting. If light is lit, press manual override button on solenoid. If generator runs, defective solenoid. Run the screed vibrators. If vibrators run, check speed of motor/generator. If speed is greater than 3600 RPM, refer to electrical troubleshooting. If speed is less than 3600 RPM, adjust the flow control valve until the motor/generator speed is 3600 RPM If 3600 RPM speed cannot be acheived by adjusting the flow control valve, (1) Clean suction strainer, check stuction hose for loose fittings, damaged hose or obstructions. (2) Check output pressure on the pump. If pressure is less than 2300 PSI, adjust pressure regulator to bring pressure up to 2300 PSI. (3) Retest generator/motor speed. Adjust flow control to maintain 3600 RPM at motor/generator. 400 & 500 Series Hydraulic Troubleshooting

65

22481 (11/01)

Technical Manual

A Terex Company

11 GPM

Remote Oil Cooler Driven From Dedicated Pump 400/500 Series Grayhound Pavers

2150 RPM

1.17 CID

2800 PSI LH Reservoir

1.2 CID

LH Reservoir LH Reservoir

2100 RPM RH rotation pump driven off front engine pad

REMOTE OIL COOLER FAN DOES NOT RUN OR RUNS SLOW Clean remote oil cooler fins to remove dirt, leaves or other air flow obstructions. Engine at full throttle. If remote cooler fan motor does not run at 2150 RPM: (1) Install at 3000 PSI gauge in-line between the pump and motor. If pressure does not reat 2800 PSI check and clean suction strainer, check suction hose for loose fittings, damaged hose and obstructions. (2) Retest hydraulic pressure. If 2800 PSI cannot be obtained, adjust pressure relief until 2800 PSI setting is reached. • If 2800 PSI setting cannot be reached, check/repair pump. • If remote cooler fan motor does not ran at 2150 RPM, check/repair motor.

400 & 500 Series Hydraulic Troubleshooting

66

22481 (11/01)

Technical Manual

A Terex Company

Remote Oil Cooler Driven From Vibrator Pump 400/500 Series Grayhound Pavers

2800 PSI

1.17 CID

2800 PSI

REMOTE OIL COOLER FAN DOES NOT RUN OR RUNS SLOW Clean remote oil cooler fins to remove dirt, leaves or other air flow obstructions. Engine at full throttle. If remote cooler fan motor does not run at 2150 RPM: (1) Install at 3000 PSI gauge in-line between the pump and motor. If pressure does not reat 2800 PSI check and clean suction strainer, check suction hose for loose fittings, damaged hose and obstructions. (2) Retest hydraulic pressure. If 2800 PSI cannot be obtained, adjust pressure relief until 2800 PSI setting is reached. • If 2800 PSI setting cannot be reached, check/repair pump. • If remote cooler fan motor does not ran at 2150 RPM, check/repair motor.

400 & 500 Series Hydraulic Troubleshooting

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A Terex Company

Remix Delivery Augers Grayhound 400 and 500 Series

This Page Intentionally Left Blank

400 & 500 Series Hydraulic Troubleshooting

68

22481 (11/01)

PAVER TECHNICAL MANUAL

Pumps-Motors-Drives Section

Technical Manual

A Terex Company

Table of Contents Pumps - Motors - Drives Cedarapids Lubricants ......................................................................................................... 1 Pressure Test Kit .................................................................................................................. 3 Component Location Map 300 Series/CR411 ..................................................................... 4 Hydraulic Pump Data 300 Series/CR411 ............................................................................ 5 Component Location Map 400 and 500 Series ................................................................... 6 Hydraulic Pump Data 400 and 500 Series ...................................................................... 7 - 8 Part Number Matrix - Pumps-Motors-Drives ...................................................................... 9 List of Repair Manuals ...................................................................................................... 10 Series 40 Pumps Information ..................................................................................... 11 - 43 Series 42 Pumps Information ..................................................................................... 44 - 78 Series 90 Pumps Information ................................................................................... 79 - 133 Vibrator Pump - S16 Rexroth .......................................................................................... 134 Auxiliary Pump - Eaton Model 70122 Piston Pump ....................................................... 135 Auxiliary Pump - Sundstrand L15 .......................................................................... 136 - 149 Fastach II Generator Drive Pump - Rexroth A10VO ....................................................... 150 Fastach II Generator Drive Pump Set-Up Procedure .............................................. 151 - 152 Stretch Electric Screed Generator Drive Pump Set-Up Procedure ........................ 153 - 156 Conveyor Drive Motor - Char-Lynn 6000 Series ............................................................ 157 Lohmann & Stolterfoht Travel Drive Unit Assembly ...................................................... 158 Travel Drive Motor .......................................................................................................... 159 Travel Drive Motor Begin of Stroke Adjustment Procedure .................................. 160 - 163 Travel Drive Motor Self-Cleaning Swivel-Time Orifices ................................................ 164 Travel Drive Motor Installation, Start-Up, & Troubleshooting .............................. 165 - 169 Travel Drive Unit Information ................................................................................ 170 - 179 Travel Drive Unit Specification Data ..................................................................... 180 - 183

Pumps - Motors - Drives

i

22483 (01/04)

Technical Manual

A Terex Company

Pumps - Motors - Drives

ii

22483 (01/04)

Pumps - Motors - Drives

1

Greases

Hydraulic Oils

EP Gear Oils

Non-EP Gear Oils

Starfak 2201

Starfak 2202

Multifak EP 2

Starfak 00

Multifak HD 00

Multifak EP 1

Pinnacle 68

Rando HD 68

Pinnacle 32

Rando HD 32

Pinnacle 46

Pinnacle EP 320

Meropa 320

Rando HD 46

Pinnacle EP 220

N/A

Meropa 100

Meropa 220

N/A

Meropa 68

Pinnacle EP 150

Pinnacle 220

Regal R&O 220

Meropa 150

Pinnacle 150

Regal R&O 150

Pinnacle 68

Regal R&O 68

Pinnacle 100

Pinnacle 46

Regal R&O 46

Regal R&O 100

Synthetic

Mineral

Texaco

Alvania EP 2

Alvania EP 1

Synthetic

Albida SLC 220

N/A

Retinax TL 00

Tellus HD 68

Tellus HD 46

Tellus HD 32

Omala HD 320

Omala HD 220

N/A

N/A

N/A

Omala RL 220

Omala RL 150

Omala RL 100

Omala RL 68

Omala RL 46

Shell

Alvania EP 00

Tellus 68

Tellus 46

Tellus 32

Omala 320

Omala 220

Omala 150

Omala 100

Omala 68

Molina 220

Molina 150

Molina 100

Turbo T 068

Turbo T 046

Mineral

Mobilux EP 2

Mobilux EP 1

Mobilux EP 023

DTE 26

DTE 25

DTE 24

Mobilgear 632

Mobilgear 630

Mobilgear 629

Mobilgear 627

Mobilgear 626

Spartan EP 320

Mobilgear SHC 320

Mobilith SHC 220

N/A

Mobilith SHC 007

SHC 526

SHC 525

Lidok EP 2

Lidok EP 1

Lidok EP 000

Nuto H 68

Nuto H 46

Nuto H 32

Spartan EP 220

Mobilgear SHC 220

SHC 524

Spartan EP 150

Spartan EP 100

Spartan EP 68

Teresstic 220

Teresstic 150

Teresstic 100

Teresstic 68

Dura-Lith EP 2

Dura-Lith EP 1

Ulti-Plex Synthetic EP 1.5

Ulti-Plex Synthetic EP 1.5

N/ A

Rykon Premium Oil 68*

Rykon Premium Oil 46*

Rykon Premium Oil 32*

Tegra Synthetic Gear EP 320

Tegra Synthetic Gear EP 220

Tegra Synthetic Gear EP 150

*A refined mineral oil with properties between mineral and synthetic

Unirex SHP 220

Unirex SHP 460

Dura-Lith EP 00

Hydraulic Oil AW 68

Teresstic SHP 68 Unirex SHP 00

Hydraulic Oil AW 46

Hydraulic Oil AW 32

Teresstic SHP 32 Teresstic SHP 46

Gear Compound EP 320

Gear Compound EP 220 Spartan Synthetic EP 320

Spartan Synthetic EP 220

Gear Compound EP 150

Gear Compound EP 100

Spartan Synthetic EP 100 Spartan Synthetic EP 150

N/A

Gear Compound EP 68 N/A

N/A

N/A

Industrial Oil 220

Teresstic SHP 220

N/A

N/A

N/A

Industrial Oil 150

Industrial Oil 100

Industrial Oil 68

N/A

Teresstic SHP 150

Teresstic SHP 100

Teresstic SHP 68

Industrial Oil 46

Teresstic SHP 46

Synthetic

Chevron Mineral

Synthetic

Exxon Teresstic 46

Mineral

Mobilgear SHC 150

N/A

N/A

SHC 630

SHC 629

DTE Oil Extra Heavy DTE Oil BB

SHC 627

DTE Oil Heavy

SHC 626

DTE Oil Heavy Medium

Synthetic N/A

Mobil DTE Oil Medium

Mineral

List of mineral/synthetic interchanges for industrial lubricants used on Cedarapids equipment.

Technical Manual

A Terex Company

Cedarapids Lubricants

22483 (01/04)

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Pumps - Motors - Drives

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Pressure Test Kit All Grayhound Pavers

45865-001-41 45865-002-27 45865-002-33

Gauge Gauge Guage

0-6000-PSI 0-100 PSI 0-600 PSI

45080-527-05

Adapter Gauge

Not Illustrated 7430-416 7430-344 7430-345 45080-527-14

45080-527-07 45080-527-15

Hose 36" Hose 10'

45080-527-17 45080-527-18 45080-527-16

45080-527-031 45080-527-061 45080-527-04

Pumps - Motors - Drives

Fitting Tee Tee Test Hose Union

#4 FS JIC Test Port #6 FS JIC Test Port #8 FS JIC Test Port

8" NPT Test Port 4" NPT Test Port #4 SAE Test Port

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Component Location Map Hydraulic Pumps - 300 Series/CR411

(Early Units) Right Side

Left Side

Vibrator Pump

Auxiliary Pump

RH Conveyor Pump

LH Conveyor Pump Pump EDC

Pump EDC

LH Travel Pump

RH Travel Pump

(Later Units) Right Side

Left Side Vibrator Pump

Generator Drive Pump (Optional)

Auxiliary Pump

RH Conveyor Pump LH Conveyor Pump Pump EDC

Pump EDC

RH Travel Pump LH Travel Pump

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Hydraulic Pump Data Grayhound 300 Series/CR411 Auxiliary Pump: L-15 Sunstrand .913 CID System Pressure: 2500 psi Flow: Approx. 10 gpm @ 2100 RPM Case Pressure: 10 psi maximum continuous (0.7 BAR) Conveyor/Traction Pump: MDT-M46 Tandem Sunstrand 2.81 CID (variable) SERIES 40 System Pressure: 5400 psi - Traction 3045 psi - Conveyor Flow (each section): Approx. 21 gpm @ 2100 RPM Charge Pressure: 350 psi - Traction 400 psi - Conveyor Case Pressure: 25 psi continuous (1.7 BAR) Cold Start: 75 psi (5.2 BAR) Vibrator Pump: S16 Rexroth Gear Pump 1.2 CID Size 10 System Pressure: 2800 psi Flow: Approx. 15 gpm @ 2100 RPM Maximum Continuous Pressure: 3000 psi (210 BAR) Generator Drive Pump (Optional) A10VO Rexroth Pump 2.75 CID Standby Pressure: 400 psi System Max. Pressure: 4000 psi

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Component Location Map Hydraulic Pumps Grayhound 400 and 500 Series Pavers

(Slat Conveyor) Auxiliary Pump Generator Drive Pump (Optional) Vibrator Pump Left Side

Right Side

Pump EDC LH Conveyor Pump

Pump EDC

LH Travel Pump

RH Travel Pump

RH Conveyor Pump

(Remix Conveyor)

Right Side

Auxiliary Pump

Vibrator Pump

Left Side LH Spreading Auger Pump

RH Spreading Auger Pump

LH Travel Pump RH Travel Pump LH Delivery Auger Pump

Pumps - Motors - Drives

RH Delivery Auger Pump

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Hydraulic Pump Data Grayhound 400/500 Series Slat & Remix Pavers Slat Conveyor Pavers

Remix Pavers

Auxiliary Pump L-15 Sunstrand .913 CID System Pressure: 2500 psi Flow: Approx. 10 gpm @ 2100 rpm Case Pressure: 10 psi max. continuous (0.7 BAR)

Auxiliary Pump L-15 Sunstrand .913 CID System Pressure: 2500 psi Flow: Approx. 10 gpm @ 2100 rpm Case Pressure: 10 psi max. continuous (0.7 BAR)

Conveyor Pump M46 Sunstrand 2.81 CID (variable) SERIES 40 System Pressure: 3800 psi Flow: Approx. 20.4 gpm @ 2100 rpm Charge Pressure: 220 psi Case Pressure: 25 psi continuous (1.7 BAR) Cold Start: 75 psi (5.2 BAR)

Remix Delivery Pump M55 Sunstrand 3.35 CID (variable) SERIES 90 System Pressure: 5500 psi Flow: Approx. 36 gpm @ 2100 rpm Charge Pressure: 350 psi Case Pressure: 40 psi continuous (3 BAR) Cold Start: 75 psi (5.2 BAR)

Traction Pump (Tire & Steel Track Pavers) M55 Sunstrand 3.35 CID (variable) SERIES 90 System Pressure: 5500 psi Flow: Approx. 36 gpm @ 2100 rpm Charge Pressure: 350 psi Case Pressure: 40 psi continuous (3 BAR) Cold Start: 75 psi (5.2 BAR)

Remix Traction Pump M41 Sunstrand 2.5 CID (variable) SERIES 42 System Pressure: 5400 psi Flow: Approx. 20.4 gpm @ 2100 rpm Charge Pressure: 350 psi Case Pressure: 25 psi continuous (1.7 BAR) Cold Start: 75 psi (5.2 BAR)

Traction Pump (Rubber Track Pavers) M55 Sunstrand 4.57 CID (variable) SERIES 90 System Pressure: 5500 psi Flow: Approx. xx gpm @ 2100 rpm Charge Pressure: 350 psi Case Pressure: 40 psi continuous (3 BAR) Cold Start: 75 psi (5.2 BAR)

Remix Spreading Pump M28 Sunstrand 1.71 CID (variable) SERIES 42 System Pressure: 3330 psi Flow: Approx. 18 gpm @ 2100 rpm Charge Pressure: 205 psi Case Pressure: 50 psi continuous (3.4 BAR) Cold Start: 150 psi (10.3 BAR)

Vibrator Pump S16 Rexroth Gear Pump 1.2 CID Size 10 System Pressure: 2800 psi Flow: Approx. 15 gpm @ 2100 rpm Case Pressure: 3000 psi max. continuous (210 BAR)

Vibrator Pump S16 Rexroth Gear Pump 1.2 CID Size 10 System Pressure: 2800 psi Flow: Approx. 15 gpm @ 2100 rpm Case Pressure: 3000 psi max. continuous (210 BAR)

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Hydraulic Pump Data Grayhound 400/500 Series Slat & Remix Pavers Slat Conveyor Pavers

Remix Pavers

Generator Drive Pump (Optional) A10VO Rexroth Pump 2.75 CID Standby Pressure: 400 psi System Max. Pressure: 4000 psi

Generator Drive Pump (Not Available on Remix) Note: There is no mounting location at this time.

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Part Number Matrix Pumps - Motors - Drives All Grayhound Pavers PART NUMBER

DESCRIPTION/FUNCTION

FORM # PAVER MODELS

COMMENT

45080-002-10

Auxiliary Pump LH Rot.-Pump Stack

19543

All

Sundstrand L15

45080-002-24

Auxiliary Pump RH Rot.-Engine Mount 19543

All

Sundstrand L15

45080-002-39

Travel/Conveyor Pump

19351

300

Sundstrand Series 40 MTD - M46

45080-002-40

Travel/Conveyor Pump

19351

300

Sundstrand Series 40 MTD - M46

45080-002-42

Travel Pump

19158

400/500

Sundstrand Series 90 - M55

45080-002-43

Conveyor Pump

19159

400/500

Sundstrand Series 40 - M46

45080-002-48

Auxiliary Pump RH Rot.-Engine Mount 20088

All

Obsolete-Substitute 45080-002-24

45080-002-49

Auxiliary Pump LH Rot.-Pump Stack

20088

All

Obsolete-Substitute 45080-002-10

45080-002-55

Remix Auger Drive Pump

21642

400/500

Sundstrand Series 42 - M28 & M41

45080-002-66

Remix Auger Drive Pump

21642

400/500

Sundstrand Series 42 - M28 & M41

45080-003-39

Vibrator Pump LH Rot.-Pump Stack

19545

All

Rexroth S16

45080-003-40

Vibrator Pump RH Rot.-Engine Mount

19545

All

Rexroth S16

N/A

All

Used to mount 45080-003-40 to engine

19378

400

Lohmann & Stolterfoht GFT 36E.1040

45080-004-75-08 Travel Motor

19161

400

Rexroth A6VE Series

45080-004-81

Conveyor Motor

19546

All

Char-Lynn 6000 Series

45080-004-85

Final Drive

19353

300

Lohmann & Stolterfoht GFT 25T2.1017

45080-004-88

Final Drive

19376

400

Lohmann & Stolterfoht GFT 36E.1051

45080-004-89

Final Drive

20267

500

Lohmann & Stolterfoht GFT 56T2.1074

45080-004-98

Final Drive

20410

300/411

Lohmann & Stolterfoht GFT 25T2.1092

45080-006-03

Final Drive

21062

400

Lohmann & Stolterfoht GFT 36E.1060

45080-006-04

Final Drive

20966

500

Lohmann & Stolterfoht GFT 44T2.1123

45080-006-05

Final Drive

21020

500

Lohmann & Stolterfoht GFT 44T2.1124

45080-006-08

Final Drive

21147

300

Lohmann & Stolterfoht GFT 25T2.1152

45080-006-20

Final Drive

21865

400/500

Lohmann & Stolterfoht GFT 40T2.9202

45080-006-22

Final Drive

21747

300

Lohmann & Stolterfoht GFT 26T2.1026

45080-006-23

Final Drive

21866

400/500

Lohmann & Stolterfoht GFT 40T2.9228

45080-006-29

Final Drive

22190

400R/500R

Lohmann & Stolterfoht GFT 40T2.9296

45080-006-31

Final Drive

22528

500

Lohmann & Stolterfoht GFT 50T3.9311

45930-001-15-08 Pump Drive Adapter Kit 45080-004-75

Final Drive

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List of Repair Manuals for Pumps - Motors - Drives The following list is the available pump, motor, and drive repair manuals should you find it necessary to completely disassemble and repair one of these components:

PUMPS - MOTORS - DRIVES (CR300 Series/411, CR400 & CR500 Series) Travel Pump 45080-002-42 ............................................................................... Form 19158 Conveyor Pump 45080-002-43.......................................................................... Form 19159 Travel Motor 45080-004-75-08 ......................................................................... Form 19161 Travel/Conveyor Pump 45080-002-40 & 45080-002-39 .................................. Form 19351 Final Drive 45080-004-85 ................................................................................. Form 19353 Final Drive 45080-004-88 ................................................................................. Form 19376 Final Drive 45080-004-75 ................................................................................. Form 19378 Auxilliary Pump 45080-002-10 & 45080-002-24 ............................................. Form 19543 Vibrator Pump 45080-003-39 ............................................................................ Form 19545 Conveyor Motor 45080-004-81 ......................................................................... Form 19546 Auxiliary Pump 45080-002-48 & 45080-002-49 .............................................. Form 20088 Final Drive 45080-004-89 ................................................................................. Form 20267 Final Drive 45080-004-98 ................................................................................. Form 20410 Final Drive 45080-006-04 ................................................................................. Form 20966 Final Drive 45080-006-05 ................................................................................. Form 21020 Final Drive 45080-006-03 ................................................................................. Form 21062 Final Drive 45080-006-08 ................................................................................ Form 21147 Remix Auger Drive 45080-002-55 & 45080-002-66 ........................................ Form 21642 Final Drive 45080-006-20 ................................................................................. Form 21865 Final Drive 45080-006-22 ................................................................................. Form 21747 Final Drive 45080-006-23 ................................................................................. Form 21866 Final Drive 45080-006-29 ................................................................................. Form 22190 Final Drive 45080-006-31 ................................................................................. Form 22528

The following pages detail some of the more common adjustment and repair procedures to the paver hydraulic pumps, motors, and drive systems. As mentioned above, this is not intended to be complete repair instructions for major component rebuilding. For that purpose, use the above listed complete manuals.

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Slat Conveyor Pumps - Series 40 Grayhound 400 and 500 Series Pavers HDC/EDC Hydraulic Neutral Adjustment

Cross-Port Line Servo Port F 500 psi Hose System Pressure Test Port B 10,000 psi Gauge

Charge Pressure Port C 1000 psi Gauge System Pressure Test Port A 10,000 psi Gauge

Charge Pressure Relief Valve Case Outlet Port D 1000 psi

Check/Relief Valve for Port A

By-Pass Valve

Charge Pump Inlet Vacuum Port E

Charge Pressure Port C 1000 psi Gauge M3

Manual Override Lever

System Pressure Port B Cross-Port Line Servo Port G M5 500 psi Hose System Pressure Port A Swash Plate Neutral Adjustment Case Drain Alternate Case Pressure Outlet Port D

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Tandem Pumps - Series 40 (M46) Conveyor/Traction Grayhound 300 Series/CR411

Conveyor High-Pressure Test Port - M2 Rear (for Port D) Use 6000 psi gauge

Conveyor Neutral Adjustment Conveyor Equalizer Servo Port - M4 Rear Use 500 psi hose

Travel High-Pressure Test Port - M1 Front (for Port A) Use 10,000 psi gauge Charge Pressure Test Port - M3 Travel High-Pressure Test Port - M2 Front (for Port B) Use 10,000 psi gauge

Conveyor High-Pressure Test Port - M1 Rear (for Port C) Use 6000 psi gauge

Case Drain Check/Relief Valve (for Port C) Conveyor Bypass Valve Check/Relief Valve (for Port B) Port B

Port A

Manual Override Lever - Travel Travel Equalizer Servo Port - M5 Front Use 500 psi hose

Pumps - Motors - Drives

12

Case Drain Swash Plate Neutral Adjustment

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Tandem Pumps - Series 40 (M46) Conveyor/Traction Grayhound 300 Series/CR411

Charge Pressure Test Port - M3 Travel High-Pressure Test Port - M2 Front (for Port B) Use 10,000 psi gauge

Travel Neutral Adjustment Travel Equalizer Servo Port - M5 Front Use 500 psi hose

Conveyor High-Pressure Test Port - M1 Rear (for Port C) Use 6000 psi gauge Travel High-Pressure Test Port - M1 Front (for Port A) Use 10,000 psi gauge

Conveyor High-Pressure Test Port - M2 Rear (for Port D) Use 6000 psi gauge

Charge Pressure Relief Valve Check/Relief Valve (for Port A) Travel Bypass Valve (Must Be Opened to Pull Paver) Charge Pump Inlet - S Check/Relief Valve (for Port D)

Port D

Port C

Manual Override Lever - Conveyor Conveyor Case Drain Conveyor Equalizer Servo Port - M5 Rear Use 500 psi hose

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Axial Piston Pumps Sundstrand Series 40 - M46 All Grayhound Series Pavers

The Following Pages are Portions of Manuals Form 19159 & 19351 Sunstrand Sauer Series 40 - M46 Service and Repair Manual

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*

* Port M4 may also be labeled "F" ** Port M5 may also be labeled "G"

**

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Remix Spreader Pumps - Series 42 (M28) Grayhound 400 and 500 Series Pavers

Servo Pressure Port G - M5 500 psi Gauge Control Neutral Adjustment (MDC/EDC)

System Pressure Port B System Pressure Test Port B - M2 10,000 psi Gauge System Pressure Port A System Pressure Test Port A - M1 10,000 psi Gauge Displacement Limiter NOTE: Do Not Adjust or Touch Unless Factory Authorized

Case Drain Port L2

Servo Pressure Port F - M4 500 psi Gauge Hydraulic Pump Neutral Adjustment

Displacement Limiter NOTE: Do Not Adjust or Touch Unless Factory Authorized

To Filter Port D

Case Drain Port D - L1 Charge Pressure Port C - M3 500 psi Gauge From Filter Port E

Pumps - Motors - Drives

System Check Relief Valve Port B Charge Pump Inlet Vacuum Port S

44

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Remix Traction Pumps - Series 42 (M41) Grayhound 400 and 500 Series Pavers Servo Pressure Port G - M5 500 psi Gauge Control Neutral Adjustment (MDC/EDC)

System Pressure Port B System Pressure Test Port B - M2 10,000 psi Gauge System Pressure Port A System Pressure Test Port A - M1 10,000 psi Gauge

Case Drain Port L2 Servo Pressure Port F - M4 500 psi Gauge

Hydraulic Pump Neutral Adjustment

Charge Pressure Port C - M3 500 psi Gauge

To Filter Port D

Case Drain Port D - L1 System Check Relief Valve Port B

From Filter Port E Charge Pump Inlet Vacuum Port S Pumps - Motors - Drives

45

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Axial Piston Pumps Sundstrand Series 42 - M28 & M41 All Grayhound Series Pavers

The Following Pages are Portions of Manual Form 21642 Sunstrand Sauer Series 42 - M28 & M41 Service and Repair Manual

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Series 42

Introduction

1. Introduction 1.1

Using This Manual

The Adjustment and Minor Repair procedures detailed herein may be performed by trained personnel without voiding the unit warranty.

placed. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. All gasket sealing surfaces must be cleaned prior to installing new gaskets.

Cleanliness is a primary means of assuring satisfactory transmission life. Cleaning parts by using a clean solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign materials and chemicals. When performing service activities, protect all exposed sealing surfaces and open cavities from damage and foreign material.

All exploded view drawings depict the 28cc frame size. For variances in the 41cc frame size, see the outline drawings in section 3. Differences in wrench size and torquing for the two frame sizes are noted in the text. Note that exterior housing screws are mostly Torx-type T30 or T45. These symbols are used within drawings: Apply petroleum jelly.

Whenever removing a service component, it is recommended that any gaskets and O-rings be re-

1.2

Lubricate with clean hydraulic oil.

Safety Precautions

Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury. The following general precautions should be taken into consideration whenever servicing a hydrostatic system.

Loss of Hydrostatic Braking Ability

Fluid Under High Pressure

WARNING When Series 42 units are used in vehicular hydrostatic drive systems, the loss of hydrostatic drive line power in any mode of operation (e.g. acceleration, deceleration or “neutral” mode) may cause a loss of hydrostatic braking capacity. A braking system which is independent of the hydrostatic transmission must, therefore, be provided which is adequate to stop and hold the system should the condition develop.

WARNING Use caution when dealing with hydraulic fluid under pressure. Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury. This fluid may also be hot enough to burn. Serious infection or reactions can develop if proper medical treatment is not administered immediately.

Flammable Cleaning Solvents

Disable Work Function

WARNING Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area where a source of ignition may be present.

WARNING Certain service procedures may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing them in order to prevent injury to the technician and bystanders.

Copyright 1996, Sauer-Sundstrand Company. All rights reserved. Contents subject to change. Printed in U.S.A.

F100003

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Series 42

Model Code

2. Model Code Refer to the model code exhibited on the unit's name plate for information regarding the configuration of the unit. saue Ames, Iowa, U.S.A. Model Code

Note: Some options listed here may not currently be available. Some options on your unit may not be listed here. This is not an order code. See the Series 42 Price Book for up-to-date ordering information.

Neumünster, Germany Typ

42L28 - C - ANN1 - 01 ANA - 2CNB - NN - NN - N N - N - NNN - NNN Model No.

Model Code

Ident Nr

428 2051 A 93 23 67890

Serial No.

Serial No.

Fabr Nr

X

XX

XX

XXXXX

Location

Year

Week

Sequence No.

MADE IN U.S.A.

A

B

C

D

1 2 A B

Series

12 34 2

1 Rotation 2 Displacement

C

D

E

F

G

123

1 2 34

1 Control Type

= None = MDC, Linear, Low Force = MDC, Non-Linear, Low Force = EDC (Electric Displacmt Contrl) = FNR (3-Pos Forwrd-Neut-Revrs) = NFP (Non-Feedback Proport'l)

NSS for MDC or PCP for EDC 2 or Connector for FNR or Style for NFP

N = None or Not Applicable 1 = NSS / Weatherpack for MDC, or PCP Style for EDC or 12V Electric for NFP 2 = 12 V DIN for FNR 3 = NSS+BAS / CW Handle Rot. / Weatherpack for MDC or Hydraulic for NFP 5 = NSS+BAS / CCW Handle Rot. / Weatherpack for MDC

Pumps - Motors - Drives

F

28 = 28 cm3 (1.71 in3) 41 = 41 cm3 (2.50 in3)

N A C E F G

Handle for MDC 4 or Connector for EDC or Connector for NFP

E

L = CCW R = CW

= 13T 16/32P Spline = 15T 16/32P Spline = 19T 16/32P Spline = 1.000 in. O.D. Straight Keyed = 1.000 in. O.D. Tapered (1.5 in/ft)

Solenoid Override with MDC 3 or EDC Input or Inching/Braking for NFP

J

K

L M

Control Response Tim 1 Port Style

P

2 Loop Flushing/Cooling

G

N = None or Not Applicable A = 12V Override / Weather Pack, or EDC Input = 14-85 mA or 400 - 1200 mA or 5-20 bar for NFP E = 12V Override / Brake Port N = None or Not Applicable 1,6 = Standard Handle fpr MDC or M/S Connector for EDC or Amp Connector for NFP 2,5 = Clevis Handle for MDC or Weather Pack for EDC

48

N

P

x1 = Fast x2 = Medium x3 = Slow

4

C D E G K

Input Shaft Config s uration

H

A,J,

= SAE Threaded sO-Ring Bos

N = None 2,3 = Loop Flushing/Cooling Shuttle = None (Ext. Charge Supply) = Suction (No Adapter Plate) = Remote Pressure (Partial Flow) = Suction (Adapter Plate)

3 Filtration

N A C G

1 Charge Pump

N = None 2 = 11 cm3/rev (0.67 in3/rev)

2 Charge Relief Setting

C = 14 bar (205 psi) F = 20 bar (280 psi)

3 Special Drive Features

N = None 1 = NFP

4 Rear Auxilliary Moundting Pa

N A B T

H

High Pressure Relief Setting Port "A"

J

High Pressure Relief Setting Port "B"

K

Loop Bypass Valve

NN 14 17 19 21 23 25 28 30 34 00

= None = SAE-A, 9 Tooth = SAE-B, 13 Tooth = SAE-A Special, 11 Tooth = Check Valve only, No HPRV = 140 bar (2030 psi) = 175 bar (2450 psi) = 190 bar (2755 psi) = 210 bar (3045 psi) = 230 bar (3330 psi) = 250 bar (3625 psi) = 280 bar (4060 psi) = 300 bar (4350 psi) = 345 bar (5000 psi) = No HPRV, No Check Valves

N = None B = Yes

L

Displacement Limiters - Side 1

M

Displacement Limiters - Side 2

N, 0 = None A, 1 = Yes, Set at Max Disp

N

Special Hardware Features

NNN = None

P

Special Non-Hardware Features

NNN = None

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Series 42

Component and Port Locations

3. Component and Port Locations 3.1

Component Locations

A pump with a manual displacement control (MDC) and no filtration adapter is shown. With non-feedback and automotive controls, the positions of the case drains vary (shown in gray). With a filtration adapter, the porting in the "Filtration Options" area varies (see section 4.16).

Control Neutral Adjustment (MDC/EDC)

Control Module (MDC Shown)

Pump Neutral Adjustment

Servo Piston Covers System Check Relief Valves

Displacement Limiters Charge Pump

Shaft Seal

Filtration Options (No Filtration Adapter Shown Here)

Auxiliary Mounting Pad

(Loop Flushing Valve) Left Side View (Side "2")

Charge Relief Valve

Right Side View (Side "1") P100101 E

Series 42 28cc Variable Pump Control Neutral Adjustment (MDC/EDC)

Control Module (MDC Shown)

Pump Neutral Adjustment

Servo Piston Covers Displacement Limiters

Charge Pump

Auxiliary Mounting Pad

System Check Relief Valves

Shaft Seal

(Loop Flushing Valve) Left Side View (Side "2")

Charge Relief Valve Right Side View (Side "1")

Filtration Options (No Filtration Adapter Shown Here) P100102 E

Series 42 41cc Variable Pump

Pumps - Motors - Drives

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Technical Manual

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Series 42 3.2

Component and Port Locations

Ports and Pressure Gauges

Proper servicing of pumps and motors requires that pressure be measured and monitored at various points in the hydraulic circuit. The Series 42 pump has several locations at which to take these measure-

Gauge Pressure Measured Port Name

ments. The following outlines show the locations of the various gauge ports. The tables show the recommended gauge size and the fitting size for each port. Refer to this page when installing pressure gauges.

Fitting

Recommended Gauge Size

System Pressure for 600 bar or 10,000 psi 9/16–18 O-Ring Fitting Ports A and B

M1 & M2

041

028

9/16–18 O-Ring Fitting

M3

Charge Pressure

60 bar or 1000 ps i

3/4–16 O-Ring Fitting

3/4–16 O-Ring Fitting

M4 & M5

Servo Pressure Case Pressure

60 bar or 1000 ps i

9/16–18 O-Ring Fitting

9/16–18 O-Ring Fitting

35 bar or 500 ps i

1-1/16–12 O-Ring Fittin g 1-5/16–12 O-Ring Fitting

Charge Pump Inlet Vacuum

1 bar, absolute or 30 in Hg Vacuum

1-1/16–12 O-Ring Fitting

L1 & L2 S

1-5/16–12 O-Ring Fitting

P100103 E

System Pressure Gauge Port M2

Servo Pressure Gauge Port M5 Servo Pressure Gauge Port M4

System Pressure Port B

Charge Pressure Gauge Port M3 (Charge Pressure Supply For No Charge Pump Option)

Case Drain Port L2 (Non-Feedback Controls)

System Pressure Port A

Case Drain Port L1 Case Drain Port L1 (Non-Feedback Controls)

Charge Pump Inlet Port S

Case Drain Port L2

System Pressure Gauge Port M1 Left Side View (Side "2")

Right Side View (Side "1")

28cc Base Unit with MDC and No Filtration Adapter

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22483 (01/04)

Technical Manual

A Terex Company

Series 42

Component and Port Locations

Servo Pressure Gauge Port M5 Servo Pressure Gauge Port M4

System Pressure Gauge Port M2

System Pressure Port B

Charge Pressure Gauge Port M3 (Charge Pressure Supply For No Charge Pump Option)

Case Drain Port L2

System Pressure Port A Charge Pump Inlet Port S

Case Drain Port L1 System Pressure Gauge Port M1 Left Side View (Side "2")

Right Side View (Side "1")

41cc Base Unit with MDC and No Filtration Adapter

P100104 E

To Filter, Port D (Pressure Filtration)

Charge Pressure Gauge Port M3 (Full Flow Pressure Filtration)

From Filter, Port E (Pressure Filtration) Charge Pressure Gauge Port M3 (Partial Flow Pressure Filtration)

Charge Pressure Gauge Port M3 (Suction Filtration) P100105 E

Filtration Adapter (28cc and 41cc Models)

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Technical Manual

A Terex Company

Series 42

Adjustments and Minor Repairs

4. Adjustment and Minor Repair Instructions 4.1

Size and Torque for Plugs and Fittings

Plug and fitting sizes are given here. Place a fresh O-ring, lightly lubricated with petroleum jelly, whenever a plug is removed. Each should be torqued as indicated. A 28cc unit with manual displacement control (MDC) is shown.

Servo Gage Port M4

11/16 in Hex 27-47 Nm (20-35 ft•lbf)

28cc: 9/16 in Int. Hex 95-135 Nm (70-100 ft•lbf) 41cc: 5/8 in Int. Hex 125-250 Nm (90-190 ft•lbf)

Case Drain Port L1 Charge Pressure Gage Port M3 (Position Varies, Refer to Filtration Options) E100001 E

Case Drain Port L2 Port N (Unused)

Charge Pump Inlet Port S Torque: 115 Nm (85 ft•lbf)

11/16 in Hex 27-47 Nm (20-35 ft•lbf) Servo Gage Port M5

System Gage Ports M1 and M2

11/16 in Hex 27-47 Nm (20-35 ft•lbf) 28cc: 9/16 in Int. Hex 95-135 Nm (70-100 ft•lbf) 41cc: 5/8 in Int. Hex 125-250 Nm (90-190 ft•lbf)

System Ports A and B 115 Nm (85 ft•lbf)

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11/16 in Hex 27-47 Nm (20-35 ft•lbf)

22483 (01/04)

Technical Manual

A Terex Company

Series 42 4.2

Adjustments and Minor Repairs

Pump “Neutral” Adjustment

The pump neutral adjustment sets the position of the servo piston and pump swashplate relative to the controlling mechanism. WARNING The following procedure requires the vehicle / machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. 1. Disconnect machine function. 2. Connect a hose between gauge ports M4 and M5 to equalize the pressures on both ends of the pump servo piston.

Pump "Neutral" Adjustment Screw

Pump "Neutral" Adjustment Seal Lock Nut

3. Install pressure gauges in gauge ports M1 and M2 to measure system pressure. 4. Start the prime mover and operate at normal speed. 5. Loosen the pump "neutral" adjustment seal lock nut [28cc⇒13 mm Hex; 41cc⇒17 mm Hex]. Turn the pump "neutral" adjustment screw [28cc⇒5 E100002 E mm Hex; 41cc⇒7 mm Hex] until the system pressure gauge readings are equal.

Pump Neutral Adjustment Screw (MDC Control Shown)

6. Turn the adjustment screw clockwise until one of the gauges registers an increase in system pressure. Note the position of the adjustment screw. Turn the screw counterclockwise until the other gauge registers an increase in system pressure. Note the position of the adjustment screw. 7. Turn the adjustment screw clockwise to a position halfway between the positions noted above. The system pressure gauges should indicate equal pressures. 8. While holding the adjustment screw in position, torque the seal lock nut [28cc⇒20-26 Nm (15-19 ft•lbf); 41cc⇒28-51 Nm (21-37 ft•lbf)] . 9. Stop the prime mover and remove the hose between gauge ports M4 and M5. Remove the pressure gauges installed in gauge ports M1 and M2. Reinstall the plugs in the gauge ports. 10. Reconnect work function. IMPORTANT If the pump is equipped with an MDC or EDC, the CONTROL "neutral" adjustment MUST also be performed before putting the pump into service (see next section). Pumps - Motors - Drives

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Technical Manual

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Series 42 4.3

Adjustments and Minor Repairs

Control “Neutral” Adjustment for MDC/EDC Controls

The control neutral adjustment aligns the pump swashplate and the control spool so that a zero angle control setting provides a zero degree swashplate setting. This adjustment should be performed whenever any part of the control or swashplate mechanisms is adjusted or removed or after the pump neutral setting (previous section) is adjusted.

MDC / EDC Control "Neutral" Adjustment Screw

WARNING The following procedure requires the vehicle / machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. 1. Disconnect the work function. Disconnect the external control linkage (for MDC) or control signal input (for EDC) from the pump. 2. Install pressure gauges in gauge ports M4 and M5 to measure pressure on the pump servo piston. 3. Start the prime mover and operate at normal speed.

MDC / EDC Control "Neutral" Adjustment Seal Lock Nut

E100003 E

Control Neutral Adjustment Screw (EDC Control Shown)

4. Loosen the CONTROL "neutral" adjustment seal lock nut (see drawing) [17 mm Hex] . Turn the control "neutral" adjustment screw [5 mm Int. Hex] until the servo piston pressure gauge readings are as close to equal as possible. 5. Turn the adjustment screw clockwise until one of the gauges registers an increase in pressure on the servo piston. Note the position of the adjustment screw. Turn the screw counterclockwise until the other gauge registers an increase in pressure on the servo piston. Note the position of the adjustment screw. 6. Turn the adjustment screw clockwise to a position halfway between the positions noted above. The servo piston pressure gauges should indicate nearly equal pressures. 7. While holding the adjustment screw in position, torque the seal lock nut [14-24 Nm (10-18 ft•lbf)]. 8. Stop the prime mover and remove the pressure gauges installed in gauge ports M4 and M5. Reinstall the plugs in the gauge ports. 9. Reconnect the external control linkage (for MDC) or control signal input (for EDC) to the pump. Reconnect the work function. Pumps - Motors - Drives

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Series 42 4.4

Adjustments and Minor Repairs

MDC Control Module

The manual displacement control (MDC) module provides control of the pump servo piston through a connection to the summing link pin within the pump housing. The following procedure shows how to remove and install the control housing. Section 4.6 explains how to remove and install the control spool and linkage. 1. Clean the external surfaces of the pump. If necessary, remove the MDC handle. 2. Remove the seven (7) control retaining screws [Torx T30] that secure the control to the pump housing. Remove the control and control gasket from the pump.

Plug for Visual Inspection

Nut Lock Washer MDC Handle

Control Retaining Screws Control Gasket Hold summing link (and control spool) in position

Note: See section 4.6 for instructions on removing/installing the control spool and linkage. 3. Clean the sealing surfaces of the control and the pump housing. Place a new gasket in position on the housing. CAUTION The control orifices are part of the control gasket. Refer to the appropriate Service Parts List to determine the correct gasket. 4. Hold the summing link pin in position while installing the control. (The spring on the control spool will tend to push the link to an extreme position.) The link pin MUST engage the slot in the control cam. A plug is provided on the MDC housing to permit visual inspection of linkage pin engagement.

Note: It may be easiest to lay the servo piston side of the control down first, then watch the link pin engage from the charge pump side of the pump.

E100004 E

MDC Control Module Assembly

Summing link pin MUST enter the slot in the control cam! E100005 E

Link Pin Into Cam Slot

5. Install and torque the control screws [15-17 Nm (11-13 ft•lbf)]. Perform Control Neutral Adjustment (Section 4.3). WARNING Failure to properly engage the link pin with the control cam will result in incorrect control operation, which may lead to loss of control of the vehicle / machine.

Link Pin Into Cam Slot Pumps - Motors - Drives

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22483 (01/04)

Technical Manual

A Terex Company

Series 42 4.5

Adjustments and Minor Repairs

EDC Control Module

The Electric Displacement Control (EDC) provides a control function through connections to the summing link pin within the pump housing. The following procedure shows how to remove and install the control housings. The next section explains how to remove and install the control spool and linkage. 1. Clean the external surfaces of the pump. If necessary, remove control input signal.

EDC Control Pressure Gauge Port X1

2. Remove the seven (7) control retaining screws [Torx T30] that secure the control to the pump housing. Note the position of the different length screws. Remove the control and control gasket from the pump.

Note: See next section for instructions on removing/installing the control spool and linkage.

EDC Control Pressure Gauge Port X2

3. Clean the sealing surfaces of the control and the pump housing. Place a new gasket in position on the housing.

EDC Module Showing Port Locations

CAUTION The control orifices are part of the control gasket. Refer to the appropriate Service Parts List to determine the correct gasket.

Control Retaining Screws (note different sizes)

4. Hold the summing link pin in position while installing the control. (The spring on the control spool will tend to push the link to an extreme position.) The link pin MUST engage the hole in the control piston fork.

Note: It may be easiest to lay the servo piston side of the control down first, then watch the link pin engage from the charge pump side of the pump. 5. Install and torque the control screws [15-17 Nm (11-13 ft•lbf)]. Perform Control Neutral Adjustment (Section 4.3).

Control Gasket Hold summing link (and control spool) in position

WARNING Failure to properly engage the link pin with control piston fork will result in incorrect control operation, which may lead to loss of control of the vehicle / machine.

Pumps - Motors - Drives

P100106 E

Summing link pin MUST enter the hole in the control piston fork!

E100006 E

EDC Control Module Assembly

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Series 42 4.6

Adjustments and Minor Repairs

MDC/EDC Control Spool, Control Linkage, and Control Neutral Adjustment Screw

The control spool, control linkage, and control neutral adjustment screw can be removed for cleaning and to change the O-rings or the seal lock nut.

Summing Link Linkage Pivot Screw

Removal of Spool, Linkage, and Adjustment Screw 1. Clean the external surfaces of the pump.

Neutral Adjustment Link

2. Remove the MDC or EDC module and the control gasket from the pump housing (see previous two sections).

Feedback Link

Control Neutral Adjust Screw

Seal Lock Nut Control Spool and Spring Note orientation!

3. Remove the summing link. 4. Remove the control spool bore plug [5/16 in Int. Hex] or screws [Torx T30], cover, and gasket. Remove the opposite bore plug [5/16 in Int. Hex], and remove the control spool and spring. 5. Remove the linkage pivot screw [4 mm Int. Hex], feedback link, and neutral adjustment link.

Opposite Bore Plug

Housing without Filtration Adapter

Control Spool Bore Plug

6. Remove the seal lock nut [17 mm Hex] and the control neutral adjustment screw [5 mm Int. Hex]. Installation of Spool, Linkage, and Adjustment Screw 1. Install the control neutral adjustment screw and seal lock nut. Do not tighten the nut. 2. Assemble the "neutral" adjustment link and feedback link, and install as shown. Install and torque the linkage pivot screw [8-15 Nm (6-11 ft•lbf)].

Housing with Filtration Adapter

Gasket

Control Spool Bore Cover

3. Lubricate and install the control spool and spring assembly noting proper orientation. WARNING The control spool and spring assembly MUST be oriented in the housing as shown for proper control operation. 4. Install and torque the control spool bore plug [4194 Nm (30-70 ft•lbf)]. Or install the control spool cover (with a new gasket) or plug, and torque the screws [15-17 Nm (11-13 ft•lbf)]. 5. Install the summing link. Hold the control spool in position while engaging the fork on the summing link with the flats on the spool. If necessary, rotate the spool to engage the summing link.

E100007 E

MDC/EDC Control Spool and Linkage

Feedback link must enter slot in servo piston Pivot screw

Slot in "neutral" adjust link must engage groove in adjusting screw

Fork on summing link must engage flats on control spool E100008 E

Servo Piston Linkage and Control Spool (Internal Parts Shown with Housing Removed)

6. Install a new control gasket. Hold the summing link and control spool in position while reinstalling the MDC or EDC (see section 4.4 or 4.5). Perform Control Neutral Adjustment (section 4.3). Pumps - Motors - Drives

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Technical Manual

A Terex Company

Series 42 4.7

Adjustments and Minor Repairs

MDC Neutral Start/Backup Alarm Switch

The Neutral Start Switch (NSS) prevents the engine and pump from being started when the pump is out of neutral. The NSS should be wired in series with the engine starting circuit. The switch contact is closed at the control handle's neutral position and opens when the control handle is rotated 1.5 to 2° from neutral.

NSS Cover NSS Control Nut NSS Cam

The Backup Alarm Switch (BUA) outputs an electronic signal when the control handle is in a reverse position. This switch is normally wired in series with an audio output. The switch contact is open until the control handle is rotated 2.6 to 3.75° in the reverse direction.

NSS Cavity

NSS with Weatherpack

CAUTION The control handle's neutral position must agree with the pump's neutral position for the NSS/BUA to work effectively (see section 4.3).

NSS with Screw Terminals E100009 E

The Neutral Start / Backup Alarm Switch assembly can be configured for three different settings. i.

NSS Assembly on MDC

A Neutral Start Switch only.

ii. A Neutral Start Switch with Backup Alarm for units where clockwise (CW) handle rotation results in "reverse" motion. iii. A Neutral Start Switch with Backup Alarm for units where counterclockwise (CCW) handle rotation results in "reverse" motion.

Yolk

The setting must be in accordance with the configuration of the unit. See the model code (section 2) if uncertain of the type of NSS you have.

NSS only

Alignment of the NSS requires a special alignment tool. Dimensions are given at right.

NSS with BUA (CW = Reverse)

Control Cam

NSS with BUA (CCW = Reverse) P100107 E

Top View of NSS Showing Cam Positions

(continued)

9/16 -18UNF 2A THD .04 x 45° Chamfer

R.125

ø .236–.030 Knurl

35.0° 1.250 .306

.354 2.000 Material: .75 DIA x 3 ETD150 (All Dimensions in inches)

P100108 E

Alignment Tool

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Series 42

Adjustments and Minor Repairs

Adjustment is performed by setting the cam position within the NSS assembly. 1. The MDC module must be removed from the pump housing. Refer to section 4.4.

NSS Cover

NSS

NSS Control Nut

2. Remove NSS [7/8 in Hex].

NSS Cam

3. Remove the NSS cover by inserting a screwdriver into the NSS cavity and popping off the cover with a hammer. Be careful not to damage the internal hardware. P100109 E

Side View of NSS and NSS Cavity

4. Remove the control nut [8 mm Hex]. 5. Use a screwdriver to pop off the cam. 6. Set cam in proper orientation according to the unit's configuration (i, ii, or iii above). 7. Screw special alignment tool in NSS cavity to hold cam in place. 8. On the underside of the MDC module, clamp a pair of locking pliers around the spring contacts of the control cam. The pliers should hold the nub on the control cam to the pin underneath. This will hold the control cam in neutral position. 9. Screw control nut on cam [4.1-6.8 Nm (3-5 ft•lbf)]. 10. Press new cover on top of cam cavity. This requires either an arbor press or a full-sized punch (punch depth = 1.06 mm (0.0417 in), punch width = 23.3 mm (0.916 in)). 11. Remove the alignment tool and the locking pliers.

Underside of MDC Module Showing Where to Clamp Locking Pliers F100202

12. Place a new lubricated O-ring on NSS. 13. Reconnect the NSS [25-29 Nm (18-22 ft•lbf)] to the MDC. 14. Reinstall MDC module onto pump housing (refer to section 4.4).

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Technical Manual

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Series 42 4.8

Adjustments and Minor Repairs

MDC Solenoid Override Valve

The solenoid override valve is a safety feature that connects both ends of the servo control piston together when the solenoid is de-energized. Thus the pump can be put into stroke only when the solenoid is energized.

Port L4 Port X7

The solenoid override with brake release includes hydraulic control of a safety brake. When de-energized, a spring-applied, hydraulically-released brake is drained through port X7. For conditions where case back-pressure on the spring-applied brake is critical, an external drain to the reservoir can be connected through port L4. The solenoid override valve can be removed to inspect and remove foreign matter. Removal 1. Remove retaining nut [9/16 in Hex].

Solenoid Override Valve Assembly

E100010 E

Solenoid Override Valve Assembly

2. Remove solenoid housing. 3. Remove retaining ring at base of solenoid.

Retaining Nut

4. Remove solenoid. This should be connected to internal spool.

Solenoid Housing

Installation 1. Replace O-ring.

Washer Retaining Ring

2. Place spring and plunger inside of solenoid.

Solenoid

3. Attach spool (male notch) to plunger (female notch).

O-Ring

4. Insert solenoid/spool assembly in solenoid override bore.

Spring Plunger

5. Snap retaining ring over base of solenoid. Spool

6. Place washer at base of solenoid. 7. Install housing and retaining nut [2-4 Nm (1.5-3.5 ft•lbf)].

E100011 E

Exploded View of Solenoid Override Assembly Pumps - Motors - Drives

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22483 (01/04)

Technical Manual

A Terex Company

Series 42 4.9

Adjustments and Minor Repairs

FNR, NFPE, and NFPH Controls

The 3-position FNR control and the electric and hydraulic non-feedback proportional (NFPE and NFPH) controls are non-feedback type controls. The FNR and NFPE controls consist of modules mounted on the pump housing. The hydraulic input for NFPH is received through ports on the top of the pump [9/16–18 SAE O-ring fitting].

NFPH Ports (Ports X1 and X2)

The non-feedback controls are set at the factory. The control modules can be removed to clean the ports and change the O-rings. The orifice plugs for the FNR and NFPE are located inside the servo piston covers. The orifice plugs for the NFPH are located in the NFPH ports. Orifice plugs may be cleaned or replaced.

E100012 E

Position of NFPH Ports

Note: Future models may contain orifice plate between module and pump housing.

Control Solenoid Control Module

Removal and Installation of FNR and NFPE Modules 1. Clean pump and module housings. 2. Remove four (4) screws retaining module to housing [4 mm Int. Hex], and remove module from pump housing.

Control Ports Locator Pin

3. Remove O-rings from the control ports. Examine ports for cleanliness. 4. Clean sealing surfaces. 5. Replace locator pin. 6. Install new O-rings. 7. Replace screws [4.7-6.1 Nm (3.5-4.5 ft•lbf]. E100013 E

Removal and Installation of FNR and NFPE Control Orifices

NFPE Assembly (FNR Similar)

Note: Future models may contain an orifice plate between module and pump housing. This will take the place of the orifice plugs beneath the servo piston cover.

Non-Feedback Control Orifice

1. Remove servo piston cover (see section 4.17). 2. Remove orifice plug [1/8 in Int. Hex]. 3. Examine orifice and port for cleanliness. 4. Install orifice plug [2.0-3.4 Nm (1.5-2.5 ft•lbf)].

E100014 E

Location of Non-Feedback Control Orifice Pumps - Motors - Drives

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A Terex Company

Series 42

Adjustments and Minor Repairs

4.10 System Check Relief Valves (High Pressure Relief, Charge Check, & Bypass Valves) The charge check, high pressure relief, and the loop bypass functions are all contained within the system check relief (SCR) valve assembly. This assembly may be removed for cleaning and installation of fresh O-rings. The model code specifies whether high pressure relief valves, combination charge check/ high pressure relief valves, and/or loop bypass valves are present or not.

With Bypass Without Bypass Valve Seat Plug

1. Remove the valve seat plugs [9 mm Int. Hex] or valve seat/bypass plugs [1 in Hex] from the pump housing.

Outer O-Ring Backup Ring

2. Remove the check poppet or relief valve assemblies from the pump housing. The smaller end of each conical spring is crimped to retain it on the check poppet or relief valve. Do not remove.

Inner O-Ring

Valve Seat Retaining Ring Standard Bypass Plunger O-Ring Valve Seat Plug Outer O-Ring Backup Ring Inner O-Ring

3. Inspect the valves and mating seats in the special plugs for damage or foreign material. CAUTION The relief valves are factory set and should not be tampered with, except for replacing the entire valve. 4. The O-ring on the standard bypass plunger may be replaced by removing the retaining ring and removing the plunger from the special valve seat plug. Remove the O-ring from the plunger and install a new O-ring. Reinstall the plunger and retaining ring.

Check Poppet or High Pressure Relief Valve Conical Spring

5. Install a new outer O-ring, new backup ring, and new inner O-ring on each valve seat plug. 6. Check that the conical springs are properly retained on the check poppets or relief valves. Install the check poppet or high pressure relief valve assemblies into the pump housing . CAUTION The conical springs MUST be correctly positioned on the check poppets or relief valves after installation for proper pump operation.

E100015 E

System Check Relief Valve Components

7. Install the valve seat plugs or valve seat/bypass plugs into the pump housing and torque [40-95 Nm (30-70 ft•lbf)].

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Series 42

Adjustments and Minor Repairs

4.11 Charge Relief Valve The charge relief valve may be removed for cleaning and installation of fresh O-rings. The pressure setting may be changed. However, note that the setting will vary for different charge flows which depends on charge pump size and pump speed. The factory setting is set relative to case pressure at 1800 rpm. The actual charge pressure will vary at different speeds. Shim Adjustable Style 1. Remove the shim adjustable charge relief valve plug [1 in Hex] from the pump housing. Remove the O-ring from the plug.

Shim Adjustable Charge Relief Valve Plug O-Ring Shims

2. Remove the spring and poppet from the housing.

Spring Poppet

3. Do not alter the shims which may be installed between the spring and valve plug, or interchange parts with another valve. Inspect the poppet and mating seat in the housing for damage or foreign material. 4. If desired, the charge relief valve setting can be changed. An approximate rule of thumb is 4 bar / 1.25 mm (58 psi / 0.050 in). The effective setting will vary.

E100016 E

To confirm the charge relief valve setting, measure charge pressure (port M3) with the pump in stroke. The charge pressure should level off when the relief setting is reached.

Shim Adjustable Charge Relief Valve Components

Approximate Relief Setting vs Shim Thickness

5. Install a new O-ring on the valve plug. Reinstall the poppet, spring, and plug (with shims and Oring) into the pump housing [55-135 Nm (40-100 ft•lbf)].

4 bar / 1.25 mm

(58 psi / 0.050 in )

(continued)

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Series 42

Adjustments and Minor Repairs

Screw Adjustable Style

Charge Relief Lock Nut

1. Before removing the screw adjustable relief valve plug, mark the plug, lock nut, and housing so as to approximately maintain the original adjustment when assembling, Remove the screw adjustable charge relief valve plug by loosening the lock nut [1-1/16 in Hex] and unscrewing the plug [8 mm Int. Hex]. Remove the O-ring from the plug.

O-Ring Screw Adjustable Charge Relief Valve Plug Spring Poppet

2. Remove the spring and poppet from the housing. 3. Inspect the poppet and mating seat in the housing for damage or foreign material. 4. Install a new O-ring on the valve plug. Reinstall the poppet and spring. Reinstall the plug with its lock nut [47-57 Nm (34-42 ft•lbf)], aligning the marks made at disassembly.

E100017 E

Screw Adjustable Charge Relief Valve Components

5. Check and adjust, if necessary, the charge pressure. For screw adjustable "anti-stall" charge relief valves, an approximate rule of thumb is 2.8 bar / quarter turn (40 psi / quarter turn).

Approximate Relief Setting vs Screw Revolution 2.8 bar / 1⁄4 turn

To confirm the charge relief valve setting, measure charge pressure (port M3) with the pump in stroke. The charge pressure should level off when the relief setting is reached.

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(40 psi / 1⁄4 turn)

22483 (01/04)

Technical Manual

A Terex Company

Series 42

Adjustments and Minor Repairs

4.12 Loop Flushing Valve The loop flushing function consists of the loop flushing shuttle valve and the loop flushing relief valve. The assemblies may be removed for cleaning and installation of new O-rings. The relief valve poppet may be exchanged for one with a different flow rating, but the relief valve shims should not be changed out unless specifically instructed so by Sauer-Sundstrand. The function also can be defeated.

Loop Flushing Relief Plug Loop Flushing Relief Plug (Defeat) O-Ring

O-Ring Shims Spring Poppet

Loop Flushing Valve 1. Remove the loop flushing valve plug from the pump housing [11/16 in Hex]. Remove the O-ring from the plug. 2. Remove the loop flushing valve spool assembly from the housing. 3. Inspect the parts for damage or foreign material. The centering spring must be securely retained to the spool by the washer.

Loop Flushing Plug (Defeat) O-Ring Defeat Spool

Loop Flushing Plug O-Ring Loop Flushing Spool Assembly

4. Install the loop flushing valve spool assembly into its bore. Install a new O-ring on the loop flushing plug and install [27-47 Nm (20-35 ft•lbf)]. Loop Flushing Relief Valve 1. Remove the loop flushing relief valve internal hex plug [5/8 in Hex] from the pump housing. Remove the O-ring from the plug.

E100018 E

2. Remove the spring and poppet from the housing. 3. Do not alter the shims which are installed between the spring and valve plug, or interchange parts with another valve. Inspect the poppet and mating seat in the housing for damage or foreign material. Inspect the orifice in the valve poppet. 4. Install a new O-ring on the valve plug. Reinstall the poppet, spring, shims, and plug (with O-ring) into the pump housing [15-34 Nm (15-25 ft•lbf)].

Loop Flushing Valve and Loop Flushing Defeat Components

Defeating Loop Flushing 1. Remove the loop flushing valve from the pump housing. 2. Install the defeat spool into the spool bore in the housing. Install the plain plug with O-ring into the housing [11/16 in Hex], and torque [27-47 Nm (20-35 ft•lbf)]. 3. Remove the charge relief valve (these parts are not necessary). 4. Install the plain hex plug with O-ring into the end cap [5/8 in Hex], and torque [15-34 Nm (15-25 ft•lbf)]. Pumps - Motors - Drives

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Series 42

Adjustments and Minor Repairs

4.13 Shaft Seal and Shaft Replacement A lip type shaft seal is used in Series 42 pumps. This seal and/or the shaft can be replaced without major disassembly of the unit. Replacement generally requires removal of the pump from the machine.

Retaining Ring Seal Carrier Assembly

1. Position the pump with the shaft facing up.

NOTE: If the unit is positioned horizontally when the shaft is removed, the cylinder block could move out of place, making shaft installation difficult. 2. Remove the retaining ring from the housing. 3. Pull out seal carrier assembly. 4. Remove the O-ring from the seal carrier. To install a new shaft only, proceed to step 8. 5. Place the seal carrier in an arbor press with the shaft bearing side down, and press out the old seal. An appropriately sized pipe spacer or socket wrench can be used as a press tool. Once removed, the seal is not reusable.

E100019 E

Shaft Seal Components

6. Inspect the seal carrier and the new seal for damage. Inspect the sealing area on the shaft for rust, wear, or contamination. Polish the sealing area on the shaft if necessary.

O-Ring

7. Press the new seal into the shaft bearing side of the seal carrier. The seal lip must face the outside of the pump. Be careful not to damage the seal. The outside diameter of the seal may be coated with a sealant (e.g. Loctite High Performance Sealant #59231) prior to installation. This aids in preventing leaks caused by damage to the seal bore in the seal carrier.

Seal

Sealant may be used on outside diameter

Seal Carrier

Inside Lip (face down)

(continued) Press Seal to bottom of Seal Carrier E100020 E

Installation of Shaft Seal

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If the shaft is not being replaced proceed to step 11.

Retaining Ring

8. Remove the shaft and roller bearing assembly from the pump or motor. The bearing assembly can be transferred to the new shaft (steps 9 and 10). 9. Remove the retaining ring that secures roller bearing assembly with a snap ring plier. Remove the roller bearing assembly. 10. Place roller bearing assembly on new shaft and secure with the retaining ring.

Roller Bearing

Key

Shaft OR

Shaft Assembly OR

11. Wrap the spline or key end of shaft with thin plastic to prevent damage to the seal lip during installation. Lubricate the inside diameter of the shaft seal with petroleum jelly. 12. Place the O-ring onto the shaft bearing and lubricate with petroleum jelly. 13. Slide the seal carrier assembly over the shaft and into the housing bore. Press against O-ring. Hold inward pressure against the shaft to compress the cylinder block spring while pressing the seal carrier into place. 14. Install the retaining ring. E100021 E

Shaft Components

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Adjustments and Minor Repairs

4.14 Auxiliary Mounting Pads The following procedure can be used to remove and install a new auxiliary mounting pad or to install a fresh O-ring for the current auxiliary mounting pad. Several auxiliary mounting pads are available. Auxiliary mounting pads are integrated into the charge pump cover. When nothing is mounted on the pads, a flange cover is attached to protect the mounting flange. This cover is removed when mounting a pump. Removal of Auxiliary Mounting Pad 1. Remove the auxiliary pump or remove the two screws retaining the flange cover ["A" Pad⇒9/16 in Hex; "B" Pad⇒3/4 in Hex]. Remove the O-ring.

Pad Cover Screws Charge Pump Cover

Aux Mount Pad Cover Retaining Screws O-Ring

2. Orient pump so that charge pump cover (auxiliary pad) is facing up.

OR

3. Remove the charge pump cover. The auxiliary pad is integrated into the charge pump cover. Use a Torx T45 male driver to remove the screws.

OR

Auxiliary Mounting Pad "A"

Note: If a different auxiliary pad is being installed, then a new drive coupling must be installed. To do this follow the instructions in the section on removing and installing the charge pump (next section).

Gasket

Auxiliary Mounting Pad "B"

Note: If the charge pump components come out with the charge pump cover refer to section 4.15 on how to properly reinstall them.

No Charge Pump Defeat

4. Install a new charge pump cover gasket.

Locating Pin 1 Charge Pump Components

5. Install the charge pump cover (auxiliary pump mounting pad is integrated in cover). Locating Pin 2

NOTE: The threaded screw holes in the auxiliary pump mounting pad used on very early production pumps with the SAE "A" pad option are drilled through into the area between the gerotor cover and charge pump cover. Any of these holes which are not used to attach the flange cover or auxiliary pump should be plugged with internal hex set screws installed hand tight to prevent the entrance of water or dirt into this area.

E100022 E

Auxiliary Pad Options and Components

6. Attach the auxiliary pump. If no pump is to be attached on an auxiliary mounting pad, the pad should be protected with a flange cover and Oring to prevent leakage.

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4.15 Charge Pump

(Screw used with "No Pad" and "A Pad" Only) Cover Retaining Screws

1. Remove auxiliary pump, if necessary. 2. Remove the screws retaining the charge pump cover to the pump housing [Torx T45] (seven (7) screws are used with the "no pad" or SAE "A" auxiliary mounting pad charge pump cover, while six (6) screws are used with the SAE "B" auxiliary mounting pad charge pump cover). Remove the charge pump cover, gasket, and the cover locating pins. 3. Remove the gerotor cover assembly from the charge pump cover or the back of the pump housing. Remove the gerotor cover O-rings. Two (2) O-rings are used on the gerotor cover of all pumps. (An additional O-ring was used on the gerotor cover of very early production pumps with the SAE "A" pad option.)

Gasket O-Rings

Geroter Cover

4. Remove the gerotor assembly from the gerotor cover or pump housing. 5. Remove the gerotor drive pin and drive coupling. Remove the gerotor cover locating pin from the pump housing. 6. Each part should be inspected separately if they are to be reused. If either of the gerotor assembly parts needs to be replaced, they must both be replaced. Always replace the O-rings and charge pump cover gasket. Inspect the journal bearing in the gerotor cover for excessive wear.

Charge Pump Cover or Auxiliary Pad

Note: For units without integral charge pumps see the last page of this section for additional information.

Geroter Assembly Drive Coupling Geroter Cover Locating Pin Charge Pump Cover Locating Pin

Geroter Drive Pin Charge Pump Cover Locating Pin

Charge Pump Components

The charge pump may be disassembled to inspect and clean, or to change the auxiliary shaft drive coupling.

7. Prior to assembly, lubricate the gerotor assembly with clean hydraulic oil. 8. Install the gerotor drive pin into the hole in the drive coupling, and retain with grease or petroleum jelly. 9. Install the drive coupling onto the pump shaft with the smaller outside diameter oriented away from the pump shaft. Different couplings are used with the different auxiliary pad options.

E100023 E

Charge Pump Components

10. Install the gerotor assembly onto the coupling.

(continued)

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11. Install the gerotor cover locating pin into the pump housing. Install the gerotor cover assembly over the gerotor. The locating pin must engage the slot in the gerotor cover.

NOTE: The charge pump rotation is determined by the location of the gerotor recess and pressure balance hole in the gerotor cover. Different gerotor covers are used for clockwise and counterclockwise rotation pumps. 12. Install new pressure balance O-rings onto the gerotor cover and retain with petroleum jelly or grease. (An additional O-ring was used on the gerotor cover of very early production pumps with the SAE "A" pad option.) 13. Install the charge pump cover locating pins and a new charge pump cover gasket. 14. Install the charge pump cover. The cover must engage the gerotor cover and the locating pins. Install the charge pump cover screws and torque evenly [36-43 Nm (26-32 ft•lbf)].

CW

CCW P100110 E

Determining Charge Pump Orientation Looking Inside of Gerotor Pump Cover

15. If necessary, reinstall auxiliary pump. For units without an integral charge pump see the next section.

(continued)

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Units without Integral Charge Pump Variable Pumps without an integral charge pump do not have a gerotor assembly, gerotor drive pin, or gerotor cover locating pin installed. The charge pump inlet port is plugged with an O-ring plug.

Cover Retaining Screws

For these units that are equipped with housings without filtration adapters, the gerotor cavity outlet is plugged with a special plug installed in a housing passage. The 3/4—16 charge inlet fitting should be torqued to 68 Nm (50 ft•lbf). For these units that are equipped with housings that include filtration adapters, the gerotor cavity outlet is plugged with an O-ring plug installed in the "To Filter" port of a "Full Filter Flow" (charge relief valve after filter) filter adapter. The 7/8—14 charge inlet fitting should be torqued to 95 Nm (70 ft•lbf).

Gasket

Charge Pump Cover or Auxiliary Pad

(Screw used with "No Pad" and "A Pad" Only)

CAUTION A "Partial Filter Flow" (charge relief valve before filter) adapter must not be used on variable pumps without an integral charge pump. If this design adapter is used, the charge relief valve will be defeated.

Geroter Cover E100024 E

Drive Coupling Charge Pump Cover Locating Pin 2

Geroter Cavity Outlet Plug (Charge Pump Defeat)

Charge Pump Cover Locating Pin 1

"No Charge Pump" Components

O-Rings

Charge Inlet

Charge Pump Inlet Plug

Charge Pump Inlet Plug

Charge Inlet (For Wrench Sizes and Torquing See Filtration Section)

No Charge Pump Option Components (Housing with Filtration Adapter)

Pumps - Motors - Drives

No Charge Pump Option Components (Housing without Filtration Adapter)

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Adjustments and Minor Repairs

4.16 Filtration Filtration of foreign matter from the hydraulic fluid is of primary importance. Dirt and foreign fluids within the hydraulic circuit will greatly reduce the life of the hydraulic equipment.

M3 Gauge Port Plug

Filtration Plate Retaining Screws

Filter-Related Pump Hardware Filtration mechanisms for the Series 42 pump may be before (suction filtration) or after (charge pressure filtration) the charge pump. Sauer-Sundstrand provides a filtration adapter to provide for each type of filtration configuration. If filtration is provided for elsewhere in the hydraulic circuit, the pump will not have a filtration adapter.

Partial Flow Pressure Filtration

Full Flow Pressure Filtration

Suction Filtration

Pumps equipped with housings without filtration adapters have an additional construction bore next to the charge relief valve which is unused and plugged [5/8 in Hex, 21-33 Nm (15-25 ft•lbf)]. When these pumps are equipped with suction filtration, the external charge inlet is plugged [5/16 in Int. Hex, 41-94 Nm (30-70 ft•lbf)]. Pumps equipped with housings that include filtration adapters have the appropriate adapter and gasket fastened to the housing with screws [Torx T30, 16 Nm (12 ft•lbf)]. The position of the M3 gauge port [11/ 16 in Hex, 11-13 Nm (8-10 ft•lbf)] will vary depending on filtration type.

Housing with Filtration Adapter

Filter Specifications Charge Inlet Plug

The selection of a filter depends on a number of factors including the contaminant ingression rate, the generation of contaminants in the system, the required fluid cleanliness, and the desired maintenance interval. A filter capable of controlling the fluid cleanliness to ISO 4406 Class 18/13 or better is recommended and may be located either on the inlet (suction filtration) or discharge (charge pressure filtration) side of the charge pump.

Construction Bore Plug

E100025 E

Housing without Filtration Adapter (Suction Filtration Only)

Filter capacity depends on desired maintenance levels. As a rough guide, a capacity in grams equal to twice the charge flow in gpm or 1/2 charge flow in l/min has been found to be satisfactory for many closed circuit systems.

Filtration Type Closed Circuit Suction Filtration or Open Circuit Return Line Filtration Systems Sharing a Reservoir with Other Gears, Clutches, or Cylinders Charge Pressure Filtration

Filter efficiency as measured by a "Beta" (β) ratio* should be as in the table at right. See Sauer-Sundstrand publication BLN-9887 or 697581 and ATI-E 9201 for more information on filtration.

Pumps - Motors - Drives

Plug

β-ratio β10 ≥ 2 β10 ≥ 10 β10 ≥ 0

* Filter ß x-ratio is a measure of filter efficiency defined by ISO 4572. It is defined as the ratio of the number of particles greater than a given size (x) upstream of the filter to number of particles greater than the same size downstream of the filter. The ßx-ratio applies to a specific particle size, measured in microns.

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4.17 Servo Piston Covers The servo piston cover can be removed to change the gasket or to inspect/change the control orifices for NFP or FNR controls (section 4.9).

Pump Neutral Ajustment Seal Lock Nut

1. On the right side (side “1”) of the pump, remove the pump “neutral” adjustment seal lock nut [13 mm Hex]. (Not necessary on side "2") 2. Remove the servo piston cover screws [Torx T30].

Servo Piston Cover Screw

Servo Piston Cover

Servo Piston Cover (Non-Feedback and Automotive controls only)

3. The left side (side "2") servo cover can be removed directly.

Pump "Neutral" Adjustment Screw

On the right side (side “1”) of the pump, the cover should be pushed away from the pump housing. It is then necessary to turn the “neutral” adjustment screw [5 mm Hex] clockwise (inward) far enough for the servo cover to clear the nearby drain port. Then pull the cover away from the housing and turn the cover counterclockwise to disengage it from the adjustment screw.

Servo Piston Cover – Right Side (Side "1")

4. Remove the gasket.

Note: FNR and NFPE control orifice plugs are located here, see section 4.9 for more information. 5. Install new gasket. 6. On the right side (side "1"), screw the servo piston cover on the neutral adjustment screw. Then, while holding the cover, turn the neutral adjustment screw CCW to engage the cover to the screw threads.

Servo Piston Cover Screws

E100026 E

Servo Piston Cover

7. Install servo piston cover screws (15-17 Nm (1113 ft•lbf)]. 8. On the right side (side "1"), loosely install neutral adjustment seal lock nut. Perform pump neutral adjustment (section 4.2).

Servo Piston Cover – Left Side (Side "2")

Servo Piston Cover Components

WARNING After installing the servo piston cover on right side (side “1”) of the pump, the pump “neutral” adjustment and control neutral adjustment MUST be performed before the vehicle / machine is put back into service. CAUTION Performance of the above procedure may adjust the position of the displacement limiter somewhat.

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4.18 Displacement Limiter Adjustment Displacement limiters can limit the maximum swashplate position. For Series 42 pumps, displacement limiters are available on one or both sides of the servo piston.

Displacement Limiter Seal Lock Nut Displacement Limiter Servo Piston Cover

Adjustment of the displacement limiters should be performed on a test stand. WARNING Care should be taken in adjusting displacement limiters to avoid undesirable speed conditions. The limiter screw must have full thread engagement in the servo piston cover, and the seal lock nut must be retorqued after every adjustment to prevent unexpected changes in operating conditions and external leakage during unit operation.

Displacement Limiter – Right Side (Side "1") (Exploded View, No Need to Remove Limiter or Nut)

1. Mount pump on test stand. 2. Loosen displacement limiter seal lock nut [13 mm Hex]. Do not remove. 3. Adjust displacement limiter [4 mm Int. Hex]. Tighten the seal lock nut every time the pump is to be tested [20-26 Nm (15-19 ft•lbf)].

Displacement Limiter Seal Lock Nut E100027 E

One full turn of the displacement limiter adjustment screw will change the displacement of the pump approximately as follows. 28cc

3.6 cc/rev

0.22 in3/rev

41cc

5.0 cc/rev

0.31 in3/rev

Servo Piston Cover

4. After reaching proper displacement tighten the seal lock nut [20-26 Nm (15-19 ft•lbf)].

Displacement Limiter – Left Side (Side "2") (Exploded View, No Need to Remove Limiter or Nut)

If necessary, repeat procedure for displacement limiter on other side.

Pumps - Motors - Drives

Displacement Limiter

Displacement Limiters

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Exploded V

5. Exploded View Parts Drawings 5.1

Shaft Options

F096 C020 C017 C018 C015

C005 C002 C003 C001 C015

F001 OR

C001

OR C001

E100028

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Series 42 5.2

Exploded V

Filtration, Charge Relief, System Relief, and Loop Flushing

(F086) (F086A) (F043) (F043A) (F040) (F042)

(F040) (F042)

(F043) (F043A) OR

F043 F043A OR

F040 F042

K001

OR K001

K005 F091 F091A

G040 G040A G041

G043 G042

K001A K001B F030 K001C F030A

K002 K006 K007

F041 K008 K009 K010

G043 G042 G041 G040A G040 OR 045A G045

F062 F061 F063 F060A F060

(F060A) (F060)

F051

OR

H005 H002 H003

J005 J002 J003

F0511

F0512 F0513 F0514 F0515 F050A F050 OR

(F091A)

F093

(F091)

(F051) (F050A) (F050)

F093A F093 F093A N002A N002 F077

E100029

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Exploded View Parts Drawings

Charge Pump, Auxiliary Pads, and Servo Covers

L010 L010A

F020 F020A

G005

(G075)

G010 G015

G002

G020 (G021) G022

G065

G075

G030 F009

G023

G001

M001 OR (M001)

OR (G001) M005 M010A (M005) (M010A)

G036

M010 OR (G080)

(M010) M020 M025 (G001)

(G036)

G085

G090

(G090) (G036)

(G080) (G085)

E100030

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Exploded View Parts Drawings

Control Options D039

D038 D037

D081

D003 D003A (D017)

D080

D082

D019 D016

D002

OR

OR D017

D056 D040 D010 D012

F035

E001

F035A

D070 OR

OR D011 D013 F036 F035

D004

E100031

F034

D081

D081 OR

D060

(F010)

F010

D090 D014 D015

D032A D032

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Slat Traction Pumps & Remix Delivery Pumps - Series 90 Grayhound 400 and 500 Series Pavers

Cross-Port Line Servo Pressure Port G 500 psi Hose

Cross-Port Line Servo Pressure Port F 500 psi Hose

High Pressure Ports A (top) & B (bottom) Use 6000 psi Gauge

Multi-Function Valve (By-Pass)

Charge Pressure Port C 500 psi High Pressure Ports A (top) & B (bottom) Use 6000 psi Gauge

Multi-Function Valve (By-Pass)

Case Drain Pressure 100 psi Port D L1

Servo Pressure Port G 500 psi Hose Cross-Port Line M5

Servo Pressure Port F 500 psi Hose Cross-Port Line M4

System Pressure Test Port B 10,000 psi Gauge M2-B Charge Pump Inlet Vacuum Port E M3

System Pressure Test Port A 10,000 psi Gauge M1-A

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Axial Piston Pumps Sundstrand Series 90 - M55 All Grayhound Series Pavers

The Following Pages are Portions of Manual Form 19158 Sunstrand Sauer Series 90 - M55 Service and Repair Manual

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Series 90

Introduction

1

1. Introduction 1.1

Use of This Manual

This manual includes information for the normal operation, maintenance, and servicing of the Series 90 family of hydrostatic pumps and motors. The manual includes the description of the units and their individual components, troubleshooting information, adjustment instructions, and minor repair procedures. Unit warranty obligations should not be affected if maintenance, adjustment, and minor repairs are performed according to the procedures described in this manual.

be available, and the unit must be thoroughly cleaned before beginning maintenance, adjustment, or repair activities. Since dirt and contamination are the greatest enemies of any type of hydraulic equipment, cleanliness requirements must be strictly adhered to. This is especially important when changing the system filter and during adjustment and repair activities. A worldwide network of Sauer-Sundstrand Authorized Service Centers is available should repairs be needed. Contact any Sauer-Sundstrand Authorized Service Center for details. A list of all Service Centers can be found in bulletin BLN-2-40527, or in brochure SAW (Ident. No. 698266).

Many service and adjustment activities can be performed without removing the unit from the vehicle or machine. However, adequate access to the unit must

1.2 Safety Precautions

Observe the following safety precautions when using and servicing hydrostatic products.

Loss of Hydrostatic Braking Ability

Fluid Under High Pressure

WARNING When Series 90 units are used in vehicular hydrostatic drive systems, the loss of hydrostatic drive line power in any mode of operation (e.g. acceleration, deceleration or “neutral” mode) may cause a loss of hydrostatic braking capacity. A braking system which is independent of the hydrostatic transmission must, therefore, be provided which is adequate to stop and hold the system should the condition develop.

WARNING Use caution when dealing with hydraulic fluid under pressure. Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury. This fluid may also be hot enough to burn. Serious infection or reactions can develop if proper medical treatment is not administered immediately.

Flammable Cleaning Solvents

Disable Work Function

WARNING Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area where a source of ignition may be present.

WARNING Certain service procedures may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing them in order to prevent injury to the technician and bystanders.

Copyright 1987, 1989, 1990, 1996, Sauer-Sundstrand Company. All rights reserved. Contents subject to change. Printed in U.S.A. 0196 H Pumps - Motors - Drives

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Series 90

Functional Description

2

2. Functional Description This section describes the operation of pumps, motors, and their various serviceable features. It is a useful reference for readers unfamiliar with the functioning of a specific system.

2.1

General Description and Cross Sectional Views

2.1.1

Variable Displacement Pumps

The Variable Displacement Pump (PV) is designed to convert an input torque into hydraulic power. The input shaft turns the pump cylinder which contains a ring of pistons. The pistons run against a tilted plate, called the swashplate. This causes the pistons to compress the hydraulic fluid which imparts the input energy into the hydraulic fluid. The high pressure fluid is then ported out to provide power to a remote function. The swashplate angle can be varied by the control piston. Altering the swashplate angle varies the displacement of fluid in a given revolution of the input shaft. A larger angle causes greater displacement which yields greater output torque for a given input. A smaller angle reduces the displacement per revolution and yields greater speed for a given input.

90000346

Series 90 Variable Displacement Pump (PV) Valve Plate

Piston

Control Piston Manual Displacement Control Roller Bearing

Input Shaft

Charge Pump

Cylinder Block

Cradle Swashplate

Series 90 PV Cross Section

2.1.2

90000189

Fixed Displacement Motor

The Fixed Displacement Motor (MF) is designed to convert an input of hydraulic power into an output torque. It operates in the reverse manner of the pump. The high pressure hydraulic fluid enters through the input port. The fluid pressure builds behind the pistons causing them to move down the swashplate (the path of least resistance). As the piston returns up the swashplate again, the fluid is allowed to exit through the exit port. The spinning pistons are housed in a cylinder which is connected to the output shaft. The output torque can be applied to a mechanical function.

90000347

Series 90 Fixed Displacement Motor (MF) Pumps - Motors - Drives

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Functional Description

Loop Flushing Valve Valve Plate

2

In the Fixed Displacement Motor the "swashplate" is fixed, so any variation in motor speed and torque must be made by the input mechanism, i.e. the pump.

Piston Roller Bearing

Output Shaft

Fixed Swashplate Cylinder Block

90000190

Series 90 MF Cross Section

2.1.3

Variable Displacement Motor

The Variable Displacement Motor (MV) operates in the same manner as the fixed motor. However, its swashplate is not fixed; it can be switched between minimum and maximum angle to amplify torque or speed like the Variable Displacement Pump.

90000348

Series 90 Variable Displacement Motor (MV)

Valve Plate

Minimum Angle Control Piston

Piston Roller Bearing

Cradle Swashplate

Output Shaft

"A"

Partial Section "A-A" Cradle Swashplate in full displacement position

"A"

Cradle Swashplate Cylinder Block Maximum Angle Control Piston

Electric 2-Position Control (Option) (4-Way, 2 Position Valve)

90000234

Series 90 MV Cross Section

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Functional Description

2

2.2 System loop

(low pressure)

Displacement control valve

Control handle

Case drain fluid Heat exchanger bypass valve

System loop Reservoir

Orificed check valve

(high pressure)

Control fluid Vacuum gauge

Suction line Heat exchanger

Reversible variable displacement pump

Servo control cylinder

Purge relief valve

Charge pressure Multi-function relief valve valve

Fixed displacement motor

to pump case Servo pressure relief valve Input shaft

Charge pump

Pump swashplate

Multi-function valve Servo control cylinder

Pump

Output shaft

Motor swashplate Loop flushing valve

Motor

The System Circuit

90000800

Circuit Diagram for Series 90 PV and Series 90 MF

The Basic Closed Circuit The main ports of the pump are connected by hydraulic lines to the main ports of the motor. Fluid flows, in either direction, from the pump to the motor then back to the pump in this closed circuit. Either of the hydraulic lines can be under high pressure. The position of the pump swashplate determines which line is high pressure as well as the direction of fluid flow.

Case Drain Line

Input

PV

MV

Output

Case Drain and Heat Exchanger The pump and motor require case drain lines to remove hot fluid from the system. The motor should be drained from its topmost drain port to ensure the case remains full of fluid. The motor case drain can then be connected to the lower drain port on the pump housing and out the top most port. A heat exchanger, with a bypass valve, is required to cool the case drain fluid before it returns to the reservoir.

Pumps - Motors - Drives

84

Flow (Bi-directional) Reservoir 90000803

Basic Closed Circuit

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Series 90 2.3

Functional Description

2

Common Features of Pumps and Motors 2.3.1

End Caps and Shafts

Series 90 pumps and motors can be supplied with a variety of end caps and shafts to allow for almost any configuration. For pumps, end caps are available with system ports on either side ("side ports") or both ports on one side ("twin ports"). Motors have end caps with ports on the face of the end cap ("axial ports") or both ports on one side ("twin ports"). See the Series 90 Technical Information manuals (BLN10029 and BLN-10030) or the Series 90 Price Book (BLN-2-40588) for information on available options. Removing the end cap will void the warranty on a Series 90 pump or motor.

2.3.2

Speed Sensors

An optional speed sensor can be installed on Series 90 pumps and motors to provide unit speed information. The sensor reads a magnetic ring wrapped about the unit's cylinder. See Sec. 4 to locate the speed sensor port. See Sec. 8.4 and 9.6 to adjust and install the sensor. 90000810

Speed Sensor

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Functional Description

2

2.4 Pump Features 2.4.1

Charge Pump

The charge pump is necessary to supply cool fluid to the system, to maintain positive pressure in the main system loop, to provide pressure to operate the control system, and to make up for internal leakage. Charge pressure must be at its specified pressure under all conditions of driving and braking to prevent damage to the transmission. The charge pump is a fixed-displacement, gerotor type pump installed in the variable displacement pump and driven off the main pump shaft. Charge pressure is limited by a relief valve (Sec. 2.4.2). 90000243

The standard charge pump will be satisfactory for most applications. However, if the charge pump sizes available for the given main pump size are not adequate, a gear pump may be mounted to the auxiliary mounting pad (Sec. 2.4.8) and supply the required additional charge flow. For repairs to the charge pump see Sec. 9.2.4.

2.4.2

Charge Relief Valve

The charge relief valve on the pump serves to maintain charge pressure at a designated level. A directacting poppet valve relieves charge pressure whenever it surpasses a certain level. This level is nominally set referencing case pressure at 1775 rpm. This nominal setting assumes the pump is in neutral (zero flow); in forward or reverse charge pressure will be lower. The charge relief valve setting is specified on the model code of the pump (Sec. 8.1.1). For repairs to the pump charge relief valve see Sec. 9.2.3.

2.4.3

PV with Charge Pump

90000349

Charge Pump Components

Case Drain Line

Charge Relief

System Check Valves

The system check valves allow pressurized flow from the charge pump to enter the low pressure side of the loop whenever system pressure dips below a certain level. This is needed as the pump will generally lose system pressure due to leakage and other factors. Since the pump can operate in either direction, two system check valves are used to direct the charge supply into the low pressure lines. The system check valves are poppet valves located in the multi-function valve assembly (next section).

System Check Valves Input

PV

PF Charge Pump

Inlet Filter Reservoir 90000804

Pump Charge System

Pumps - Motors - Drives

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Technical Manual

A Terex Company

Series 90

Functional Description 2.4.4

2

Multi-Function Valves

All Series 90 pumps include two multi-function valves. The multi-function valve incorporates the system check valve, the pressure limiter valve, the high pressure relief valve, and the bypass valve in a replaceable cartridge. These functions are described separately. There are two multi-function valve cartridges in each Series 90 pump to handle functions in either direction. See Secs. 8.1.2 and 9.2.1 for adjustments and repairs.

NOTE: Some multi-function valves do not include a pressure limiter valve. 90000243

2.4.5

PV showing location of Multi-Function Valves High Pressure Relief / Check Valve Poppet

Pressure Limiter Housing

Series 90 pumps are designed with a sequenced pressure limiting system and high pressure relief valves. When the preset pressure is reached, the pressure limiter system acts to rapidly destroke the pump so as to limit the system pressure. For unusually rapid load application, the high pressure relief valve acts to immediately limit system pressure by cross-porting system flow to the low pressure side of the loop. The pressure limiter valve acts as the pilot for the high pressure relief valve spool. The high pressure relief valve is sequenced to operate at approximately 35 bar (500 psi) above the level that initiates the pressure limiter valve.

Check Valve Poppet

Pressure Limiter Lock Nut Pressure Limiter Adjustment Screw

Bypass Actuator

Pressure Limiter Poppet Seat Pressure Limiter Valve Poppet

90000806

Cross Section of Multi-Function Valve

Both the pressure limiter sensing valves and relief valves are built into the multi-function valves (see above).

To Control Multi-Function Valve

NOTE: For some applications, such as dual path vehicles, the pressure limiter function may be defeated so that only the high pressure relief valve function remains.

Bypass Hex Adjustment

Servo Piston

Pressure Limiter and High Pressure Relief Valves

Port "A" Servo Pressure Relief Valves Port "B"

2.4.6

Bypass Valves

Servo Piston Charge Pressure Relief Valve

The bypass valves ("tow") can be operated when it is desired to move the vehicle or mechanical function when the pump is not running. The valve is opened by manually resetting the valve position (Sec. 8.1.3).

Multi-Function Valve 90000801

Circuit Diagram Showing Pressure Control Mechanisms

Pumps - Motors - Drives

The bypass valves are built into the multi-function valves (see above).

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Technical Manual

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Series 90 2.4.7

Functional Description

2

Displacement Limiters

Series 90 pumps sizes 042 - 250 are designed for optional mechanical displacement (stroke) limiters. The maximum displacement of the pump can be limited in either direction. The setting can be set as low as 0° in either direction. For instructions on adjustment see Sec. 8.1.5.

90000244

PV with Displacement Limiters

2.4.8

Auxiliary Mounting Pads

Auxiliary mounting pads are available on all Series 90 pumps. SAE A through E and H mounts are available (availability varies by pump size). This pad is used for mounting auxiliary hydraulic pumps and for mounting additional Series 90 pumps to make tandem pumps. The pads allow for full through-torque capability. 90000242

PV with Auxiliary Mounting Pad

2.4.9

Filtration Options

All Series 90 pumps are available with provisions for either suction or charge pressure filtration (integral or remote mounted) to filter the fluid entering the charge circuit. (See Sec. 6 for more information.) Suction Filtration The suction filter is placed in the circuit between the reservoir and the inlet to the charge pump. When suction filtration is used, a reducer fitting is placed in the charge pressure gauge port (M3). Filtration devices of this type are provided by the user.

90000243

PV with Suction Filtration (No filtration device attached)

Charge Pressure Filtration The pressure filter may be integrally mounted directly on the pump or a filter may be remotely mounted for ease of servicing. A 200 mesh screen, located in the reservoir or the charge inlet line, is recommended when using this filtration option. A non-bypass filter is preferred on all types of filtration.

Pumps - Motors - Drives

88

90000246

90000247

PV with Integral Charge Pressure Filtration (left) PV with Remote Charge Pressure Filtration (right, filter attached remotely)

22483 (01/04)

Technical Manual

A Terex Company

Series 90

Functional Description

2

2.4.10 Pressure Override (POR) - 180 Frame Size Only To Control

Multi-Function Valve Pressure Override Control Valve

Bypass Hex Adjustment

Port "A" Shuttle Valve Port "B"

Multi-Function Valve

Charge Pressure Relief Valve 90000802

Pressure Override - 180 Frame Size Only

Pumps - Motors - Drives

89

The pressure override valve (POR) modulates the control pressure to the displacement control to maintain a pump displacement which will produce a system pressure level less than or equal to the POR setting. For unusually rapid load application, the high pressure relief valve function of the multifunction valves is available to also limit the pressure level. The pressure override consists of a three-way normally open valve which operates in series with the pump displacement control. Control supply pressure is normally ported through the pressure override valve to the displacement control valve for controlling the pump's displacement. If the system demands a pressure above the override setting, the POR valve will override the control by reducing the control pressure supplied to the displacement control. As the control pressure reduces, the internal forces tending to rotate the swashplate overcome the force of the servo pistons and allow the pump's displacement to decrease.

22483 (01/04)

Technical Manual

A Terex Company

Series 90

Functional Description

2.5

Pump Control Options

2.5.1

Manual Displacement Control (MDC)

The manual displacement control converts a mechanical input signal to a hydraulic signal using a springcentered four-way servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction. The MDC is designed so the angular position of the pump swashplate is proportional to the rotation of the control input shaft. For adjustments see 8.2.1; for repairs see 9.3.2, 9.3.8.

2

90000237

PV with Manual Displacement Control

Non-Linear MDC The non-linear manual displacement control (photo in Sec. 8.2.2) operates in the same manner as the regular MDC except that it is designed so the change in the angular position of the pump swashplate progressively increases as the control input shaft is rotated toward its maximum displacement position. For adjustments see Sec. 8.2.2; for repairs see 9.3.2. 90000239

Solenoid Override Valve A solenoid override valve option (not shown here) is available for MDC. This safety feature will return the swashplate to zero displacement position when activated. The valve may be set in either a normally open or normally closed mode. For repairs see 9.3.3, 9.3.4.

PV with Manual Displacement Control and Neutral Start Switch

Neutral Start Switch (NSS) The neutral start switch is an optional feature available with MDC. When connected properly with the vehicle’s electrical system, the neutral start switch ensures that the prime mover can be started only when the control is in a neutral position. For adjustments see Sec. 8.2.3.

2.5.2 Hydraulic Displacement Control (HDC) The hydraulic displacement control uses a hydraulic input signal to operate a spring-centered four-way servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction. The HDC is designed so the angular position of the pump swashplate is proportional to input pressure. For adjustments see 8.2.4; for repairs see 9.3.5, 9.3.8. Pumps - Motors - Drives

90

90000240

PV with Hydraulic Displacement Control

22483 (01/04)

Technical Manual

A Terex Company

Series 90

Functional Description 2.5.3

2

Electric Displacement Control (EDC)

The electric displacement control is similar to the hydraulic displacement control with the input signal pressure controlled by a pressure control pilot (PCP) valve. The PCP valve converts a DC electrical input signal to a hydraulic signal which operates a springcentered four-way servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction. The control is designed so the angular position of the swashplate is proportional to the EDC input. For neutral adjustment see Sec. 8.2.4; for repairs see Sec. 9.3.5, 9.3.6, and 9.3.8.

90000241

PV with Electric Displacement Control

2.5.4

Automotive Control (AC and AC II)

Automotive Control (AC) allows a vehicle to be driven in a manner similar to an automobile with an automatic transmission. The AC control includes a three-position electric control to provide direction control.

90000353

PV with Automotive Control (AC)

.

The AC II control can be combined with a manual, hydraulic, or electric displacement control to provide both direction control and control over maximum vehicle speed. It may also be combined with a 3position electric control to provide direction control.

2.5.5

3-Position (FNR) Electric Control

This control utilizes a 12 or 24 VDC electrically operated spool valve to port pressure to either side of the pump displacement control piston. Energizing one of the solenoids will cause the pump to go to its maximum displacement in the corresponding direction.

F000645

PV with Automotive Control Type II (AC II)

All functions of the three-position (FNR) electric control are preset at the factory. For repairs, see Sec. 9.3.7

90000354

PV with 3-Position (FNR) Electric Control Pumps - Motors - Drives

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Series 90

Technical Specifications

3

3. Technical Specifications 3.1

General Specifications

Design Variable Pumps and Motors: Axial piston pump of variable displacement, cradle swashplate design. Fixed Motors: Axial piston motor with fixed displacement, fixed swashplate design. Type of Mounting (per SAE J744) SAE flange, Size "B" mounting pad, 2 bolts SAE flange, Size "C" mounting pad, 4 bolts Cartridge flange, 2 bolts (for motor only)

3.2

Port Connections (See Sec. 4.2 for exact specs.) Main pressure ports: SAE flange, Code 62 Remaining ports: SAE straight thread O-ring boss Direction of Rotation Clockwise or counterclockwise (motors are bidirectional) Installation Position Installation position is discretionary. The housing must always be filled with hydraulic fluid, so note position of drain ports.

Circuit Diagrams

L2

M3 M1

A

M3 X5

Vg max

A M1

M5 M4

M2

B L1 M2 B L1

S

MV with electrohydraulic twoposition control

L2

PV with charge pump and manual displacement control

L2

M3

A

M1

B

M2

L1

MF

Pumps - Motors - Drives

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90000811 90000812 90000813

22483 (01/04)

Technical Manual

A Terex Company

Series 90 3.3

Technical Specifications

3

Hydraulic Parameters

System Pressure Range

Temperature Range1

Maximum Pressure

480 ba r

[6960 psi]

Minimum, Intermittent or Cold Start

-40°C

[-40°F]

Rated Pressure

420 ba r

[6000 psi]

Maximum, Continuous 4 10 °C

[220°F]

Maximum, Intermittent 5 11 °C

[240°F]

Charge Pump Inlet Vacuum (on pumps only) Maximum Vacuum, Continuous

0.7 bar abs [10 in Hg]

Maximum Vacuum, Cold Start

0.2 bar abs [25 in Hg]

Fluid Viscosity Limits

Case Pressure

Minimum, Intermittent

5 mm 2/s

[42 SUS]

Minimum, Continuous

6.4 mm2/s

[47 SUS]

Minimum, Optimum

13 mm2/s

[70 SUS]

110 mm2/s

[510 SUS]

Maximum, Continuous

3 ba r

[44 psi]

Maximum, Continuous

Maximum, Intermittent or Cold Start

5 bar

[73 psi]

Maximum, Intermittent 1600 mm2/s [7400 SUS] or Cold Start

Hydraulic Fluid Refer to SAS publication BLN 9887 or Publication SDF (Id. No. 697581). Also refer to publication ATIE 9101 for information relating to biodegradable fluids

Filtration Required cleanliness level: ISO 4406 Class 18/13 or better. Refer to SAS publications BLN 9887 or Publication SDF (Id. No. 697581) and ATI-E 9201.

1. At hottest point in system, normally the case drain port. Temperature and viscosity limits must be met simultaneously.

Pumps - Motors - Drives

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Series 90 3.4

Technical Specifications

3

Technical Data

Table 1 - Variable Displacement Pumps Dimension Displacement (maximum) Minimum speed Rated speed*

3

030 PV 042 PV 055 PV 075 PV 100 PV 130 PV 180 PV 250 PV

cm in3

30.0 1.83

42.0 2.56

55.0 3.35

75.0 4.57

100.0 6.10

130.0 7.93

180.0 10.98

250.0 15.25

min-1 (rpm)

500

500

500

500

500

500

500

500

-1

4200

4200

3900

3600

3300

3100

2600

2300

-1

min (rpm)

Maximum speed*

min (rpm)

4600

4600

4250

3950

3650

3400

2850

2500

Max. attainable speed* at max. disp.

min-1 rpm)

500

5000

4700

4300

4000

3700

3150

2750

Nm / bar lbf•in/1000 psi

0.48 290

0.67 380

0.88 530

1.19 730

1.59 970

2.07 1260

2.87 1750

3.97 2433

kg lb

28 62

34 75

40 88

49 108

68 150

88 195

136 300

154 40

Theoretical torque at max. disp. Weight (Base Unit)

Table 2 - Fixed and Variable Displacement Motors Dimension 3

030 MF 042 M F 055 M F 075 M F 100 M F 130 M F 055 M V 075 M V

Displacement (maximum)

cm in3

30.03 1.83

42.0 2.56

55.0 3.35

75.0 4.57

100.0 6.10

130.0 7.93

55.0 3.35

75.0 4.57

Displacement (minimum)

cm3 in3

—

—

—

—

—

—

19.0 1.16

26.0 1.59

at max. disp.

mi n-1 (rpm)

420 0

420 0

390 0

360 0

330 0

310 0

390 0

360 0

at min. disp.

mi n-1 (rpm)

—

—

—

—

—

—

4600

425 0

at max. disp.

mi n-1 (rpm)

460 0

460 0

425 0

395 0

365 0

340 0

425 0

395 0

at min. disp.

mi n-1 (rpm)

—

—

—

—

—

—

5100

470 0

min-1 (rpm)

500 0

500 0

470 0

430 0

400 0

370 0

470 0

430 0

Nm / bar lbf•in/1000 psi

0.48 290

0.67 380

0.88 530

1.19 730

1.59 970

2.07 1260

0.88 530

1.19 730

l / min gal / min

138 36.5

193 51

234 62

296 78

365 96

442 117

234 62

296 78

Max. corner power

kW hp

111 149

155 208

187 251

237 318

292 392

354 475

224 300

282 378

Weight (SAE Flange)

kg lb

11 24

15 34

20 45

26 57

34 74

45 99

39 86

44 98

Weight (Cartridge Motor)

kg lb

—

17 37

26 57

33 72

—

—

40 88

46 101

Rated speed*

Maximum speed*

Max. attainable speed* at max. disp. Theoretical torque at max. disp. Maximum flow at max. disp.

* = Refer to Series 90 Technical Information manual for definitions

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Series 90

Pressure Measurement

4

4. Pressure Measurement 4.1

Required Tools

The service procedures described in this manual for Series 90 pumps and motors can be performed using common mechanic's tools. Special tools, if required are shown.

4.2

Pressure gauges should be calibrated frequently to ensure accuracy. Snubbers are recommended to protect pressure gauges.

Port Locations and Pressure Gauge Installation

The following sections list the ports for each type of hydraulic unit. The recommended pressure gauge and fitting are also specified.

4.2.1

Port M1

M2

Variable Pump

Function

1000 bar or 10 000 psi Gauge 9/16—18 O-Ring Fitting

System Pressure Port "B"

1000 bar or 10 000 psi Gauge 9/16—18 O-Ring Fitting

Servo Pressure

Port

Recommeneded Gauge Siz and Fitting

System Pressure Port "A"

M3 Charge (M6) Pressure M4 M5

Outline drawings showing port locations follow the tables.

Function

L1 Case L2 Pressure

Recommeneded Gauge Siz and Fitting 10 bar or 100 psi Gauge SAE O-Ring Fitting: 030, 042 7/8—14 055, 075, 1-1/16—12 100 130

50 bar or 1000 psi Gauge 9/16—18 O-Ring Fitting

1-5/16—12

180, 250 1-5/8—12

50 bar or 500 psi Gauge 9/16—18 O-Ring Fitting

X1 HDC / EDC X2 Pressure

50 bar or 1000 psi Gauge 7/16 — 20 O-Ring Fitting or 9/16 — 18 O-Ring Fitting

X3 Ext. Control Pressure

50 bar or 1000 psi Gauge 9/16 — 18 O-Ring Fitting

S

Vacuum Gauge, Tee into Inlet Line

Charge Pump Inlet

SAE O-Ring Fitting: 030, 042 1-1/16 — 12 055, 075 1-5/16 — 12 100, 130, 1-5/8 — 12 180 250

Pumps - Motors - Drives

95

1-1/2 SAE Split Flange

22483 (01/04)

Technical Manual

A Terex Company

Series 90

Pressure Measurement

4

Servo / Displacement Cylinder Pressure Gauge Port M4 External Control Pressure Supply Port X3

Charge Pressure Gauge Port M3 Case Drain Port L1 System Pressure Port "B"

Servo / Displacement Cylinder Pressure Gauge Port M5 90000814

Top View

System Pressure Port B System Pressure

Case Drain Port L1

External Control Pressure Supply Port X3

Gauge Port M2 Speed Sensor Charge Inlet Pressure

System Pressure Gauge Port M1

Charge Pump Inlet Port S

System Pressure Port A

Case Drain Port L2

Left Side View

Charge Pressure Gauge Port M3 Right Side View 90000815 90000816

PV with Side Port End Cap and Manual Displacement Control

Pumps - Motors - Drives

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Series 90

Pressure Measurement

4

Charge Pressure Gauge Port M6 (Before Filter) Port E (From Filter) Port D (To Filter)

Charge Pressure Gauge Port M3 (After Filter)

Charge Pressure Gauge Port M3 (After Filter)

Rear View

PV with Side Port End Cap and Remote Pressure Filtration

Rear View

90000817 90000818

PV with Side Port End Cap and Integral

Pressure Filtration

Charge Pressure Gauge Port M3

Case Drain Port L1 System Pressure Gauge Port M2

External Control Pressure Supply Port X3

Case Drain Port L1

System Pressure Port B

Servo / Displacement Cylinder Pressure Gauge Port M4

Charge Pump Inlet Port S System Pressure Port A Servo / Displacement Cylinder Pressure Gauge Port M5 Top View

System Pressure Gauge Port M1 Case Drain Port L2

Left Side View

90000819 90000820

PV with Twin Port End Cap and Manual Displacement Control

Pumps - Motors - Drives

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Series 90

Start-Up

5

5. Initial Start-Up Procedure

The following start-up procedure should always be followed when starting-up a new Series 90 installation or when restarting an installation in which either the pump or motor had been removed. WARNING The following procedure may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before moving the vehicle/machine. Prior to installing the pump and/or motor, inspect the units for damage incurred during shipping and handling. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid. Fill the reservoir with recommended hydraulic fluid. This fluid should be passed through a 10 micron (nominal, no bypass) filter prior to entering the reservoir. The use of contaminated fluid will cause damage to the components, which may result in unexpected vehicle/machine movement. See the publications BLN-9887 and SDF 697581 for further related information. The inlet line leading from the reservoir to the pump must be filled prior to start-up. Check inlet line for properly tightened fittings and make sure it is free of restrictions and air leaks. Be certain to fill the pump and/or motor housing with clean hydraulic fluid prior to start up. Fill the housing by pouring filtered oil into the upper case drain port. Install a 50 bar (or 1000 psi) pressure gauge in the charge pressure gauge port (see Sec. 4.2 for location) to monitor the charge pressure during start-up. It is recommended that the external control input signal (linkage for MDC, hydraulic lines for HDC, or

Pumps - Motors - Drives

98

electrical connections for EDC) be disconnected at the pump control until after initial start-up. This will ensure that the pump remains in its neutral position. WARNING Do not start prime mover unless pump is in neutral position (0° swashplate angle). Take precautions to prevent machine movement in case pump is actuated during initial start up. “Jog” or slowly rotate prime mover until charge pressure starts to rise. Start the prime mover and run at the lowest possible RPM until charge pressure has been established. Excess air may be bled from the high pressure lines through the high pressure system gauge port. Once charge pressure has been established, increase speed to normal operating RPM. Charge pressure should be as indicated in the pump model code (see Sec. 8.1.1). If charge pressure is inadequate, shut down and determine cause for improper pressure. Refer to Troubleshooting Sec. 7. WARNING Inadequate charge pressure will affect the operator’s ability to control the machine. Shut down the prime mover and connect the external control input signal. Also reconnect the machine function if disconnected earlier. Start the prime mover, checking to be certain the pump remains in neutral. With the prime mover at normal operating speed, slowly check for forward and reverse machine operation. Charge pressure may slightly decrease during forward or reverse operation. Continue to cycle slowly between forward and reverse for at least five minutes. Shut down prime mover, remove gauges, and plug ports. Check reservoir level and add filtered fluid if needed. The transmission is now ready for operation.

22483 (01/04)

Technical Manual

A Terex Company

Series 90

Fluid and Filter Maintenance

6

6. Fluid and Filter Maintenance

To ensure optimum service life of Series 90 products, regular maintenance of the fluid and filter must be performed. Contaminated fluid is the main cause of unit failure. Care should be taken to maintain fluid cleanliness while performing any service procedure.

ManoVacuummeter Hydraulic fluid reservoir Charge pump

Filter

Check the reservoir daily for proper fluid level, the presence of water (noted by a cloudy to milky appearance, or free water in bottom of reservoir), and rancid fluid odor (indicating excessive heat). If either of these conditions occur, change the fluid and filter immediately.

Adjustable Charge pressure relief valve

to low pressure side and control

To pump case

It is recommended that the fluid and filter be changed per the vehicle/machine manufacturer’s recommendations or at the following intervals:

P000797 E

Suction Filtration Schematic

System with a sealed-type reservoir

2000 hours

System with a breathingtype reservoir

500 hours

Screen

Hydraulic fluid reservoir

It may be necessary to change the fluid more frequently than the above intervals if the fluid becomes contaminated with foreign matter (dirt, water, grease, etc.) or if the fluid has been subjected to temperature levels greater than the recommended maximum. Never reuse fluid.

Adjustable Charge pressure relief valve

Charge pump to low pressure side and control

The filter should be changed whenever the fluid is changed or whenever the filter indicator shows that it is necessary to change the filter.

To pump case

Filter

Filters can be in either pressure filtration or suction filtration configurations. For suction filtration, filters should have a Beta-ratio of β10>2. For charge pressure filtration, filters should have a Beta-ratio of β10>10. See Sauer-Sundstrand publication BLN-9887 or 697581 and ATI-E 9201 for more information on filtration.

P000798 E

Charge Pressure Filtration Schematic (Partial Flow)

Pumps - Motors - Drives

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Series 90

Troubleshooting

7

7. Troubleshooting This section provides general steps to follow if certain undesirable system conditions are observed. Follow the steps in a section until the problem is solved. Some of the items will be system specific. For areas covered in this manual, a section is referenced. Always observe the safety precautions listed in Sec. 1.2 and related to your specific equipment.

7.1

"Neutral" Difficult or Impossible to Find Item

Description

Action

1. Check input to pump control.

Input to control module is operating improperly.

Check control input and repair or replace as necessary.

2. Check pump displacement control.

Control linkages are not secure, control orifices are blocked, etc.

Adjust, repair, or replace control module as necessary (8.2 and 9.3).

3. Repair pump.

7.2

or

Consult a Sauer-Sundstrand Authorized Service Center.

replace

System Operating Hot Item

1. Check oil level in reservoir.

Description Insufficient hydraulic fluid will not meet cooling demands of system.

2. Inspect changer.

ex-

Heat exchanger not sufficiently cooling the system.

Check air flow and input air temperature for heat exchanger. Clean, repair or replace heat exchanger.

3. Check charge pressure.

Low charge pressure will overwork system.

Measure charge pressure (4.2). Inspect and adjust or replace charge relief valve (8.1.1 and 9.2.3). Or repair leaky charge pump (9.2.4).

4. Check charge pump inlet vacuum.

High inlet vacuum will overwork system. A dirty filter will increase the inlet vacuum. Inadequate line size will restrict flow.

Check charge inlet vacuum (4.2). If high, inspect inlet filter and replace as necessary. Check for adequate line size, length or other restrictions.

5. Check system relief pressure settings.

If the system relief settings are too low, the relief valves will be overworked.

Verify settings of pressure limiters and high pressure relief valves and adjust or replace multi-function valves as necessary (8.1.2, 9.2.1)

6. Check for internal leakage in motor.

Leakage will reduce low side system pressure and overwork the system.

Monitor motor case flow without loop flushing in the circuit (use defeat spool 9.4.1.3). If flow is excessive, replace motor.

7. Check system pressure.

High system pressure will overheat system.

Measure system pressure (4.2). If pressure is high reduce loads.

heat

8. Replace transmission. Pumps - Motors - Drives

Action Fill reservoir to proper level.

Replace pump and motor. 100

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Series 90 7.3

Troubleshooting

7

Transmission Operates Normally in One Direction Only Item

Description

Action

1. Check input to pump control.

Input to control module is operating improperly.

Check control input and repair or replace as necessary.

2. Check pump displacement control.

Control linkages are not secure, control orifices are blocked, etc.

Repair or replace control module as necessary (8.2 and 9.3).

3. Interchange system pressure limiters, high pressure relief valves, and system check valves.

Interchanging the multi-function valves will show if the problem is related to the valve functions contained in the multi-function valves.

Interchange multi-function valves. If the problem changes direction, repair or replace the valve on the side that does not operate (8.1.2 and 9.2.1).

4. Check charge pressure.

If charge pressure decays in one direction the loop flushing valve may be “sticking” in one direction.

Measure charge pressure in forward and reverse (4.2). If pressure decays in one direction, inspect and repair the motor loop flushing valve (9.4.1.1).

7.4

System Will Not Operate in Either Direction Item

Description

Action

1. Check oil level in reservoir.

Insufficient hydraulic fluid to supply system loop.

Fill reservoir to proper level.

2. Check input to pump control.

Input to control module is operating improperly.

Check control input and repair or replace as necessary.

3. Check pump displacement control.

Control linkages are not secure, control orifices are blocked, etc.

Repair or replace control module as necessary (8.2 and 9.3).

4. Ensure bypass valve(s) are closed.

If bypass valve(s) is open, the system loop will be depressurized.

Close bypass valves (8.1.3). Replace multifunction valve if defective (9.2.1).

5. Check charge pressure with pump in neutral.

Low charge pressure insufficient to recharge system loop.

Measure charge pressure with the pump in neutral (4.2). If pressure is low, go to step 6; otherwise continue with step 5.

6. Check charge pressure with pump in stroke.

Low charge pressure with the pump in stroke indicates a motor charge relief valve or system pressure relief valve may be improperly set.

Measure charge pressure with pump in stroke (4.2). If pressure is low, adjust or replace motor charge relief valve (8.3.1 and 9.4.1.2), otherwise go to step 9.

7. Inspect pump charge relief valve.

A pump charge relief valve that is leaky or set too low will depressurize the system.

Adjust or replace pump charge relief valve as necessary (8.1.1, 9.2.3)

8. Check charge pump inlet filter.

A clogged filter will undersupply system loop.

Inspect filter and replace if necessary.

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9. Check charge pump.

A malfunctioning charge pump will provide insufficient charge flow.

Repair or replace the charge pump (9.2.4). If OK go to last step.

10. Check pump displacement control.

Control linkages are not secure, control orifices are blocked, etc.

Repair or replace control module as necessary (8.2 and 9.3).

11. Check system pressure.

Low system pressure will not provide power necessary to move load.

Measure system pressure (4.2). Continue with next step.

12. Check system multifunction valves.

Defective multi-function valves will cause system pressure to be low.

Repair or replace multi-function valve(s) (9.2.1). Replace pump and motor.

13. Replace transmission.

7.5

Low Motor Output Torque Item

Description

Action

1. Check system pressure at motor.

Low system pressure at the motor will reduce torque.

Measure system pressure at motor (4.2). If pressure limiter setting is low, increase setting.

2. Variable motor stuck at minimum displacement.

Minimum motor displacement yields low output torque.

Check control supply pressure (4.2.3) or repair displacement control (9.5). Check motor control orifices (9.5.4).

3. Check for internal leakage.

Internal leakage will reduce system pressure.

Check for leakage in O-rings, gaskets, and other fittings (9.1.1 and others). Repair unit as required, or replace leaky unit.

4. Replace transmission.

7.6

Replace pump and motor.

Improper Motor Output Speed Item

Description

1. Check oil level in reservoir.

Insufficient hydraulic fluid will reduce motor speed.

Fill oil to proper level.

2. Check charge pressure.

Incorrect charge pressure can result in a low speed motor.

Measure charge pressure (8.1.1), adjust charge system as necessary (9.2.3 and 9.2.4).

3. Check pump output flow.

Incorrect outflow will affect output speed. Incorrect output flow indicates the swashplate is out of position.

Measure pump output flow by teeing into outflow hose. Check for proper pump speed and see that the pump is in full stroke.

4. Check variable motor displacement control.

If variable motor displacement control is not functioning correctly, variable motor swashplate may be in wrong position.

See if variable motor displacement control is responding. If not, repair or replace control (9.5).

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Action

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Series 90 7.7

Troubleshooting

7

Excessive Noise and/or Vibration Item

Description

1. Check oil in reservoir.

Insufficient hydraulic fluid will lead to cavitation.

Fill reservoir to proper level.

2. Air in system.

Air bubbles will lead to cavitation.

Look for foam in reservoir. Check for leaks on inlet side of system loop. Afterwards, let reservoir settle until bubbles are gone. Run system at low speed to move system fluid to reservoir. Repeat.

3. Check pump inlet vacuum.

High inlet vacuum will create noise. A dirty filter will increase the inlet vacuum.

Inspect and replace filter as necessary. Check for proper suction line size.

4. Inspect shaft couplings.

A loose shaft coupling will cause excessive noise.

Replace loose shaft coupling in charge pump (Sec. 9.2.4) or replace pump or motor.

5. Inspect shaft alignment.

Unaligned shafts will create excessive frictional noise.

Align shafts.

7.8

Action

System Response is Sluggish Item

Description

1. Check oil level in reservoir.

Insufficient hydraulic fluid will reduce output pressure.

Fill reservoir to proper level.

2. Check multi-function valves’ pressure settings.

Incorrect pressure settings will affect system reaction time.

Adjust or replace multi-function valves (8.1.2 and 9.2.1).

3. Check pump inlet vacuum.

High pump inlet vacuum will reduce system pressure.

Measure charge inlet vacuum (4.2). If high replace inlet filter.

4. Check prime mover speed.

Low engine speed will reduce system performance.

Adjust engine speed.

5. Check charge and control pressures.

Incorrect charge or control pressures will affect system performance.

Measure charge and control pressures and correct if necessary (4.2 and others).

6. Check system internal leakage.

Internal leakage will reduce system pressure.

Check for leakage in O-rings, gaskets, and other fittings (9.1.1 and others). Replace pump and motor.

7. Replace transmission.

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Inspections and Adjustments

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8. Inspections and Adjustments This section offers instruction on how to perform inspections and adjustments on pump and motor components. Read through the entire related section before beginning a service activity. Refer to Sec. 4 for location of gauge ports and suggested gauge size.

8.1

Pump Adjustments

8.1.1 Charge Relief Valve Adjustment The following procedure explains how to check and adjust the charge relief valve. (For description see Sec. 2.4.2.) WARNING The following procedure may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) in order to prevent injury to the technician and bystanders. 1. To measure pump charge pressure, install a pressure gauge in the pump charge pressure gauge port (M3). Also install a gauge to measure case pressure (tee into L1 or L2 or use servo gauge port). Operate the system with the pump in “neutral” (zero displacement) when measuring pump charge pressure. 2. The table on the following page shows the acceptable pump charge pressure range for some nominal charge relief valve settings (see sample model code at right). These pressures assume 1775 pump rpm and a reservoir temperature of 49°C (120°F ), and are referenced to case pressure (see footnote on next page). Smaller displacement charge pumps will produce charge pressure readings in the lower portion of the range, while larger displacement charge pumps will produce readings in the higher portion of the range.

90000243

Charge Pressure Gauge Port (Reducer fitting shown - if filtration device attached, see Sec. 4.2.1 for alternate location of this port)

90L055 EA 1 N 6 S 3 C6 C 03 HNN 35 35 24

Nominal Charge Pressure Setting

Model Code on Unit Name Plate (“24 bar”)

(continued)

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Inspections and Adjustments

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Model Code Measured Charge Pressure* Setting (stated range ± 1.7 bar [± 25 psi]) 20 bar

20.1 to 21.2 bar [291 to 308 psi]

24 bar

24.0 to 25.2 bar [348 to 365 psi]

28 bar

27.8 to 29.0 bar [403 to 420 psi]

NOTE: These pressures assume a pump speed of 1775 rpm. At higher pump input speeds (with higher charge flows) the charge pressure will rise over the rated setting. 3. Earlier production Series 90 pumps are equipped with a shim adjustable charge relief valve. Shim kits are available from Sauer-Sundstrand. Adjustment of charge pressure is accomplished by removing the plug [1 inch Hex] and changing the shim thickness behind the spring. The plug for this type of charge relief valve should be torqued to 68 Nm (50 lbf•ft). 90000262

Shim Adjustable Charge Pressure Relief Valve (Pump)

Later production Series 90 pumps are equipped with an external screw adjustable charge relief valve. Adjustment of the charge pressure is accomplished by loosening the lock nut (with a 1-1/ 16 inch hex wrench for 030 through 100 units, or a 1-5/8 inch hex wrench for 130 through 250 units), and turning the adjustment plug with a large screwdriver or a 1/2 inch hex wrench. Clockwise rotation of the plug increases the setting, and counterclockwise rotation decreases the setting (at a rate of approximately 3.4 bar (50 psi) per turn). The lock nut for this type of charge relief valve should be torqued to 52 Nm (38 lbf•ft).

90000264

Screw Adjustable Charge Pressure Relief Valve (Pump)

4. Once the desired charge pressure setting is achieved, remove the gauges.

* This is the actual charge pressure port gauge reading minus the case pressure port gauge reading.

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Inspections and Adjustments

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8.1.2 Multi-Function Valve Pressure Adjustment Adjustment of the pressure limiter setting and the high pressure relief valve setting is accomplished simultaneously. The latter is automatically set approximately 35 bar (500 psi) above the former. For description of multi-function valve see Sec. 2.4.4. In order to adjust the pressure limiter setting, the motor output shaft must be locked so it does not rotate. This may be accomplished by locking the vehicle’s brakes or rigidly fixing the work function so it cannot rotate. WARNING Take necessary precautions that the motor shaft remains stationary during the adjustment procedure.

90000258

Multi-Function Valves on PV

1. Install two 1000 bar (or 10,000 psi) pressure gauges in the high pressure gauge ports (M1 and M2). Install a 50 bar (or 1000 psi) pressure gauge in the pump charge pressure gauge port (M3). 2. Start the prime mover and operate at normal speed. 3. Loosen locking nut (smallest hex on multi-function valve) with a 10 mm wrench for earlier 042 through 100 frame size units, a 19 mm wrench for 030 and later 042 through 100 frame size units, or a 13 mm wrench for earlier 130 frame size units. 4. Insert a 3 mm (early 042 through 100 units), 5 mm 030 and (late 042 through 100 units), or 4 mm (earlier 130 units) internal hex wrench into the pressure adjusting screw.

NOTE: A plastic dust plug is installed in the adjusting screw on 030 and late 042 through 250 units. 5. The factory preset pressure limiter setting is shown on the model code as at right. It is referenced to charge pressure, so the pressure limiter setting is the difference between the high and low pressure sides of the system loop. Activate or move the control input so that pressure increases in the high pressure side of the closed circuit to the pressure limiter pressure setting. The pressure limiter setting is reached when the pressure stops increasing and remains steady at a given pressure level (as shown on the gauges).

(continued)

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90000259

Loosen Pressure Adjusting Screw Lock Nut

90L055 EA 1 N 6 S 3 C6 C 03 HNN 35 35 24 Pressure Limiter Setting Ports A and B (differential pressure in 10s of bars, e.g. “35” = 350 bar)

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Series 90

Inspections and Adjustments

8

6. Return the pump to its “neutral” (zero flow) position and adjust the pressure limiter setting by rotating the pressure adjusting screw with the internal hex wrench. Clockwise rotation of the pressure adjustment screw will increase the pressure setting, and counterclockwise rotation will decrease the pressure setting. Each complete rotation of the pressure adjusting screw changes the pressure setting by approximately 83 bar (1200 psi) on earlier 042 through 100 units, or by approximately 93 bar (1350 psi) on 030 and later 042 through 100 units. 7. To verify the actual pressure setting, actuate or move the control input so that the pump again develops pressure in the high pressure circuit to the newly adjusted pressure limiter pressure setting, and read the high pressure gauge. Then allow the pump to return to its “neutral” position. The pressure in the high pressure circuit should return to the charge pressure setting.

90000260

Rotate Pressure Adjusting Screw

8. While holding the pressure adjusting screw stationary, tighten the pressure adjusting screw lock nut to 3 Nm (26 in•lbf) on early production units, or 16 Nm (12 ft•lbf) on late production units. Do not over-torque. 9. Shut down the prime mover, remove the gauges and install the gauge port plugs. Replace the plastic dust plugs (if used). The same procedure is used for setting the pressure limit of the other multi-function valve, but the control input signal must be activated or moved in the opposite direction so that high pressure develops in the opposite side of the closed circuit. Tighten Lock Nut

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90000260

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8.1.3 Engaging the Bypass Function The bypass function (see Sec. 2.4.6 for description) is performed by the multi-function valve cartridges. The prime mover should be shut down when opening or closing the bypass valves. The bypass valves on both of the multi-function valves must be opened to engaged the bypass function. 1. Using a 1-1/16 inch (030 through 100) or 1-3/8 inch (130 through 250) wrench on the middle sized hex of the multi-function valve cartridge, and a 1-1/4 inch (030 through 100) or 1-5/8 inch (130 through 250) wrench on the large hex to prevent rotation of the cartridge assembly, rotate the middle hex three revolutions counterclockwise to open the bypass valve. Do not rotate more than 3-1/2 revolutions, as additional rotation will permit external leakage. 2. For units with an MDC-type control, prior to moving the vehicle or otherwise causing the motor shaft to turn, move the control handle of the manual displacement control on the pump to the maximum full forward position. Hold the handle in this position during bypass valve operation. WARNING “Tow” at extremely low speeds and for short distances only.

90000266

Loosening and Rotating Bypass Hex on MultiFunction Valve

Bypass Actuator

Opening Bypass Valve Allows Flow to Circuit through Multi-Function Valves

the middle

90000827

Multi-Function Valve with Bypass Function Engaged

3. To close the bypass valve, rotate the middle hex clockwise until it is seated. Then torque the middle hex to 41 Nm (30 lbf•ft).

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8.1.5 Displacement Limiter Adjustment The maximum displacement can be limited in either direction (see Sec. 2.4.7). 1. Loosen the seal lock nut retaining the displacement limiter adjusting screw. Frame Size 042 - 100 130 180 - 250

Wrench Size 13 mm 17 m m 19 mm

2. Rotate the adjusting screw. Frame Size 042 - 100 130 180 - 250

Internal Hex Wrench Size 4 mm 5 mm 6 mm

Loosen Displacement Limiter Lock Nut

90000267

Rotating the adjusting screw clockwise will decrease the maximum displacement of the pump while rotating the adjusting screw counterclockwise will increase the maximum displacement. WARNINGS Care should be taken in adjusting displacement limiters to avoid undesirable flow or speed conditions. See Sec. 3 for speed and pressure limits. The seal lock nut must be retorqued after every adjustment to prevent an unexpected change in operating conditions and to prevent external leakage during unit operation.

90000268

Rotate Adjusting Screw

3. After establishing the desired maximum displacement setting, tighten the lock nut on the adjusting screw as follows. Frame Size 042 - 100 130 180 - 250

Torque 24 Nm [18 lbf•ft] 48 Nm [35 lbf•ft] 125 Nm [92 lbf•ft]

4. One turn of the adjusting screw will change the maximum displacement approximately as follows. Frame Size 030

Approx Change in Disp per Rev of Adjusting Screw 2.8 cm3/rev (0.17 in3/rev)

042

3.4 cm3/rev (0.21 in3/rev)

055

4.0 cm3/rev (0.25 in3/rev)

075

5.0 cm3/rev (0.31 in3/rev)

100

6.0 cm3/rev (0.37 in3/rev)

130

9.0 cm3/rev (0.55 in3/rev)

180

12.5 cm3/rev (0.76 in3/rev)

250

17.3 cm3/rev (1.06 in3/rev)

Pumps - Motors - Drives

90000269

Tighten Lock Nut

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Inspections and Adjustments

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8.2.4 Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment The “neutral” adjustment is the only adjustment that can be made on hydraulic and electric displacement controls. All other functions are preset at the factory. For functional descriptions see Sec. 2.5.2 and 2.5.3. This adjustment must be made on a test stand or on the vehicle/machine with the prime mover operating. The neutral adjustment is performed by adjusting a neutral adjusting shaft (earlier production EDCs) or a neutral adjusting screw (HDCs and current production EDCs).

90000240

PV with Hydraulic Displacement Control

WARNING The following procedure requires the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) in order to prevent injury to the technician and bystanders. 1. Install two 50 bar (or 1000 psi) gauges in each of the two displacement control cylinder gauge ports (M4 and M5). Disconnect the external control input (hydraulic or electronic) from the control. Start the prime mover and operate at normal speed.

90000241

PV with Electric Displacement Control

2. Loosen the lock nut with a 17 mm hex wrench for the neutral adjusting shaft or with a 10 mm or 13 mm hex wrench for the neutral adjusting screw.

(continued)

90000249

Install Gauges in Displacement Control Cylinder Gauge Ports

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3. Using a 5 mm internal hex wrench for the neutral adjusting shaft or a 3 mm or 4 mm internal hex wrench for the neutral adjusting screw, rotate clockwise until the pressure increases in one of the pressure gauges. Note the angular position of the wrench. Then rotate the neutral adjusting shaft or screw counterclockwise until the pressure increases by an equal amount on the other gauge. Again note the angular position of the wrench. 4. Rotate the neutral shaft or adjusting screw clockwise half the distance between the locations noted above. The gauges should read the same pressure (case pressure), indicating that the control is in its “neutral” position.

90000250

90000252

Rotate Neutral Adjusting Tighten Neutral Adjusting Shaft (Early Production) Shaft Lock Nut (Early Production)

5. Hold the neutral adjusting shaft or screw stationary. Tighten the neutral shaft lock nut (early production controls) to 22 Nm (195 in•lbf). Tighten the neutral adjusting screw lock nut (later production controls) to 7 Nm (62 in•lbf) for the 6 mm screw or 13.6 Nm (120 in•lbf) for the 8 mm screw. Do not overtorque the nut. 6. Once the neutral position is set, stop the prime mover, remove the gauges, and install the gauge port plugs. Reconnect the external control input.

90000251

90000318

Rotate Neutral Adjusting Tighten Neutral Adjusting Screw (Later Production) Screw Lock Nut (Later Production)

90000355

90000356

Rotate Neutral Adjusting Tighten Neutral Adjusting Screw (Current Screw Lock Nut (Current Production HDC) Production HDC)

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Minor Repair Instructions

9

9. Minor Repair Instructions Minor repairs may be performed, following the procedures in this section, without voiding the unit warranty. Although specific models are shown, these procedures apply to all series and types of units in the Series 90 Family. Cleanliness is a primary means of ensuring satisfactory transmission life, on either new or repaired units. Cleaning parts by using a solvent wash and air drying is adequate, providing clean solvent is used. As with any precision equipment, the internal mechanism

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and related items must be kept free of foreign materials and chemicals. Protect all exposed sealing surfaces and open cavities from damage and foreign material. It is recommended that all gaskets and O-rings be replaced when servicing. All gasket sealing surfaces must be cleaned prior to installing new gaskets. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.

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A Terex Company

Series 90

Minor Repair Instructions

9

Hydrostatic Unit Outlines for Minor Repair Reference Charge Pressure Relief Valve Filtration Options

Control Control Orifices Charge Pump

Shaft Seal

Main Shaft

(Auxiliary Pad)

Speed Sensor

Right Side View

Left Side View

90000843

SAE Flange PV

Charge Pressure Relief Valve

Charge Pressure Relief Valve

Loop Flushing Valve

Loop Flushing Valve

Shaft Seal

Shaft Seal (Speed Sensor)

(Speed Sensor)

Left Side View

Left Side View 90000844

SAE Flange MF

Control Orifices Charge Pressure Relief Valve Loop Flushing Valve

Cartridge Flange MF

Maximum Angle Displacement Limiter

Control Orifices Charge Pressure Relief Valve Loop Flushing Valve

Shaft Seal

Control

Maximum Angle Displacement Limiter Shaft Seal

Control

Minimum Angle Displacement Limiter

(Speed Sensor on Opposite Side of Housing)

Left Side View

Minimum Angle Displacement Limiter

Left Side View 90000845

SAE Flange MV

Cartridge Flange MV

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Minor Repair Instructions

9

Pump and Motor Minor Repair

9.1.1 Plug / Fitting Torques If any plugs or fittings are removed from the pump or motor during servicing, they should be torqued as indicated in the accompanying table. Always install new O-rings before reinstalling the plugs or fittings. CAUTION Plugs or fittings installed into aluminum housings should always be torqued to the lower values specified for internal hex plugs of the same size.

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Description

Torque

7/16 — 20 O-Ring 9/16 inch Hex Wrench

20 Nm (15 lbf•ft)

7/16 — 20 O-Ring 3/16 inch Internal Hex Wrench

12 Nm (9 lbf•ft)

9/16 — 18 O-Ring 11/16 inch Hex Wrench

37 Nm (27 lbf•ft)

9/16 — 18 O-Ring 1/4 inch Internal Hex Wrench

23 Nm (17 lbf•ft)

3/4 — 16 O-Ring 7/8 inch Hex Wrench

68 Nm (50 lbf•ft)

3/4 — 16 O-Ring 5/16 inch Internal Hex Wrench

68 Nm (50 lbf•ft)

7/8 — 14 O-Ring 1 inch Hex Wrench

95 Nm (70 lbf•ft)

7/8 — 14 O-Ring 3/8 inch Internal Hex Wrench

68 Nm (50 lbf•ft)

1-1/16 — 12 O-Ring 1-1/4 inch Hex Wrench

163 Nm (120 lbf•ft)

1-1/16 — 12 O-Ring 9/16 inch Internal Hex Wrench

115 Nm (85 lbf•ft)

1-5/16 — 12 O-Ring 1-1/2 inch Hex Wrench

190 Nm (140 lbf•ft)

1-5/16 — 12 O-Ring 5/8 inch Internal Hex Wrench

129 Nm (95 lbf•ft)

1-5/8 — 12 O-Ring 1-7/8 inch Hex Wrench

224 Nm (165 lbf•ft)

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Series 90

Minor Repair Instructions

9

9.1.2 Shaft Seal and Shaft Replacement Lip type shaft seals are used on Series 90 pumps and motors. These seals and/or the shafts can be replaced without major disassembly of the unit. However, replacement usually requires removal of the pump or motor from the machine. 1. Position the pump with the shaft facing up.

NOTE: If the unit is positioned horizontally when the shaft is removed, the cylinder block could move out of place, making shaft installation difficult.

90000270

Remove Screws Holding Retainer Plate and Seal Carrier

2. Remove the three or four screws holding the retainer plate and seal carrier to the housing, using a 10 mm hex wrench (030 and 042 units), a 5 mm internal hex wrench (055 through 100 units), or a 6 mm internal hex wrench (130 through 250 units). Remove the retainer plate.

90000271

Remove Seal Carrier

NOTE: Certain earlier production units use a one piece retainer plate and seal carrier. 3. After removing the screws, the spring force on the shaft may move the seal carrier out of its bore by approximately 5 mm (1/4 inch). If the seal carrier does not move from its bore after removing the screws, pry it from its bore as shown and/or lightly tap the end of the shaft with a soft mallet. 4. Remove the O-ring from the seal carrier. 5. Place seal carrier and seal in an arbor press and press out old seal.

90000272

Press Out Old Seal

90000273

New Seal Installed in Carrier

6. Inspect the seal carrier, the new seal and the Oring for any damage or nicks. 7. Using the arbor press, press the new seal into seal carrier. Be careful not to damage the seal.

Screw Retaining Plate Seal Carrier Seal

Seal Carrier [1 Piece]

The outside diameter of the seal may be lightly coated with a sealant (such as Loctite High Performance Sealant #59231) prior to installation. This aids in preventing leaks caused by damage to the seal bore in the seal carrier.

Screw

Seal O-Ring

90000846

Series 90 Shaft Seal Components

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Minor Repair Instructions

8. Inspect the sealing area on the shaft for rust, wear, or contamination. If the shaft is not being replaced proceed to step 12.

Roller Bearing Retaining Assembly Ring Tapered Shaft Roller Bearing

Splined Shaft

OR

9. Remove shaft and roller bearing assembly from pump or motor. The bearing assembly can be transferred to the new shaft. 10. Remove the retaining ring that secures roller bearing assembly with a snap ring pliers. Remove the roller bearing assembly.

OR OR

Straight Key Shaft 90000866

Fixed Motor Shaft Configuration Roller Bearing Assembly

11. Place roller bearing assembly on new shaft and secure with the retaining ring. 12. Wrap spline or key end of shaft with plastic film to prevent damage to the sealing lip on the seal during installation.

9

Splined Shaft

OR

Retaining Ring Roller Bearing Tapered Shaft

OR

13. Prior to assembly, lubricate the O-ring on the O.D. of the seal carrier and the I.D. of the seal with clean petroleum jelly. 14. Assemble the seal carrier and seal over the shaft and into the housing bore. Install the retainer plate (if used). 15. Install the screws and torque to 16 Nm (12 ft•lbf) for 030 through 100 pumps, 32 Nm (24 ft•lbf) for 130 through 250 pumps, 9.5 Nm (7 ft•lbf) for 055 through 100 motors, and 22.5 Nm (16.6 ft•lbf) for 130 motors.

NOTE: Torque the screws in a sequenced pattern then recheck.

OR

Straight Key Shaft

90000867

Variable Pump Shaft Configuration

Roller Bearing Assembly Splined Shaft

OR

Retaining Ring

Tapered Shaft

90000868

Variable Motor Shaft Configuration

90000274

Install Seal Carrier

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90000275

Torque Retainer Screws

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Series 90 9.2

Minor Repair Instructions

9

Pump Minor Repairs 9.2.1 Multi-Function Valve Cartridges 1. The multi-function valve cartridge is removed with a 1-1/4 inch (030 through 100 pumps) or a 15/8 inch (130 through 250 pumps) hex wrench on the largest hex on the cartridge. 2. Inspect cartridge for damage to parts and Orings.

90000276

Remove Multi-Function Valve Cartridge

The multi-function valve cartridge may be disassembled for cleaning. However, if the pressure limiter housing assembly is disassembled, the pressure settings must be readjusted. Usually, if there is contamination problem, it will be in the valve seat assembly. If it is not necessary to clean the interior of the cartridge, proceed to step 7.

90000277

Install and Torque Cartridge

NOTE: Multi-function valve components are not sold separately as service parts (except O-rings). 3. On early versions of the multi-function valves, the valve seat assembly is held by a retaining ring. Remove retaining ring with a snap ring pliers.

90000278

Multi-Function Valve Cartridge Components (Earlier Production)

On late versions, the valve seat section is pressed over a lip. Place the cartridge in a vise and pry the lower section off with an appropriate tool. Maintain sufficient control to prevent the contents from flying loose.

90000279

Multi-Function Valve Cartridge Components (Later Production)

4. Remove pressure limiter lock nut and bypass actuator.

High Presssure Pressure Limiter Relief/Check Pressure Limiter Valve Spring Valve Poppet Lock Nut Check Valve Pressure Limiter Spring Seat Poppet Housing

Pressure Limiter Adjustment Screw

6. Clean and inspect all disassembled parts. 7. Reassemble with new, lightly lubricated O-rings by reversing the above procedure. For early versions assemble with the retaining ring. For late versions, place the cartridge in a vise and press on lower assembly. CAUTION The pressure settings must be readjusted after disassembling the pressure limiter housing of the multi-function valve cartridge (see Sec. 8.2.1)

Spring Valve Pressure Limiter Seat Valve Poppet Pressure Limiter Poppet Seat Bypass

8. Install cartridge in multi-function valve cavity and torque to 89 Nm (66 ft•lbf) for 030 through 100 pumps and 279 Nm (206 ft•lbf) for 130 through 250 pumps. Do not overtorque the multi-function valve cartridge.

Actuator 90000869

Multi-Function Valve Cartridge Sectional View

Pumps - Motors - Drives

5. Unscrew the pressure limiter adjustment screw from the bypass actuator.

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9.2.2 Pressure Override Valve (Option for 180 Frame Size)

Pressure Override Valve

a

1. Remove the four screws attaching the pressure override valve to the pump end cap with a 5 mm internal hex wrench. Remove the O-rings.

Screws

O-rings

2. Inspect valve for damage to parts. 3. Install new O-rings. Install the valve onto the pump end cap and torque the screws to 16 Nm (12 ft•lbf).

90000870

9.2.3 Charge Relief Valve Pressure Override Valve Components

The pump charge relief valve may be shim adjustable (early models) or screw adjustable (late models). 1. Remove the shim adjustable charge relief valve plug with a 1 inch hex wrench. Before removing the screw adjustable relief valve plug, mark the plug, lock nut, and housing so as to approximately maintain the original adjustment when assembling. Remove the screw adjustable charge relief valve plug by loosening the lock nut with a 1–1/16 inch wrench for 030 through 100 units or a 1-5/8 inch for 130 through 250 units. Unscrew the plug with a large screwdriver or 1/2 inch hex wrench. 2. Remove the spring and relief valve poppet.

90000280

Remove Charge Relief Valve (Shim Adjustable)

90000262

Shim Adjustable Charge Relief Valve

3. Inspect the poppet and mating seat in the end cap for damage or foreign material. When inspecting shim adjustable valves, do not alter the shims or interchange parts with another valve. 4. Install the poppet and spring. For shim adjustable valves, install the plug and torque to 68 Nm (50 ft•lbf). For screw adjustable valves, install the plug with its lock nut, aligning the marks made at disassembly, and torque the lock nut to 52 Nm (38 ft•lbf).

90000264

90000265

Remove Charge Relief Screw Adjustable Charge Valve (Screw Adjustable) Relief Valve

Check the charge pressure and adjust, if necessary (8.1.1).

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9.2.4 Charge Pump The following procedure shows how to remove and install a charge pump. 1. For pumps with an auxiliary mounting pad, remove the four screws holding the pad to the end cap and remove the pad. Refer to the Auxiliary Mounting Pad Installation instructions (next section) for details. 90000282

Remove Retainer Screws

Discharge

Gerotor Assembly

NOTE: Late production pumps may not have the smaller screws installed to secure the end cap to the pump housing when the large screws are removed. On these pumps, secure the end cap to the pump housing with a clamp to avoid gasket damage.

90000284

Remove Charge Pump Cover

Discharge

Alignment Pin

CAUTION Do not allow the force of the cylinder block spring and swashplate leveler springs to separate the end cap from the pump housing. Gasket damage and external leakage may result.

Inlet Inlet Alignment Pin Gerotor Assembly Outer Eccentric Ring Left Hand Rotation (Outside Looking Into Pump)

Orienting Gerotor Outer Ring and Alignment Pin (CCW Rotation)

Outer Eccentric Ring Right Hand Rotation (Outside Looking Into Pump) 90000871

2. Using a 10 mm (030 through 100 pumps) or a 13 mm (130 through 250 pumps) hex wrench, remove the six screws holding the charge pump cover retainer.

Orienting Gerotor Outer Ring and Alignment Pin (CW Rotation)

3. Remove the retainer and the charge pump cover. For pumps with an auxiliary mounting pad, remove the auxiliary drive coupling. Note the orientation of the gerotor.

(continued)

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Standard End Cap Screw

4. Remove the charge pump shaft and charge pump drive key.

Alignment Pin Charge Pump Assembly

5. Remove the spacer plate(s), if present (intermediate production pumps only).

Thin Port Plate Key

Remove the charge pump outer port plate, if present (early and intermediate production pumps).

Thick Port Plate

Shaft

Eccentric Ring Gerotor Assembly

O-ring Cover

Journal Bearing

Remove the charge pump gerotor assembly. 6. Remove the outer eccentric ring and alignment pin.

Cover Retainer 90000872

Retainer Screw

Charge Pump Components (Early Production)

7. Remove the inner port plate. Standard End Cap Screw

8. Inspect all parts for abnormal wear or damage.

NOTE: If a different displacement charge pump is being installed, the gerotor assembly, gerotor outer eccentric ring, and inner port plate (early and late production pumps) or outer spacer plate(s) (intermediate production pumps) must be replaced together. If different thickness port plates are used in an early production charge pump assembly, the thicker plate is the inner port plate (installed next to the pump end cap).

Alignment Pin Thin Port Plate Charge Pump Assembly

Eccentric Ring

Key

Gerotor Assembly

Shaft

Thin Port Plate

O-ring

Spacer Plate(s)

Cover Journal Bearing Cover Retainer Retainer Screw

90000873

Charge Pump Components (Intermediate Production) Standard End Cap Screw Alignment Pin Charge Pump Assembly Key Shaft

Port Plate

O-ring

Eccentric Ring Gerotor Assembly

Cover

Journal Bearing Cover Retainer Retainer Screw

90000874

Charge Pump Components (Late Production) Standard End Cap Screw Spacer Shaft O-ring Cover Plug Journal Bearing Cover Retainer Retainer Screw

90000875

"No Charge Pump" Components Pumps - Motors - Drives

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Discharge

Minor Repair Instructions

Gerotor Assembly Alignment Pin

Installing the Charge Pump Be sure to install the charge pump in the proper orientation. If unsure of charge pump rotation, refer to the model code.

Discharge

Inlet

Inlet

NOTE: The charge pump rotation is determined by the orientation of the gerotor assembly outer eccentric ring and the location of the alignment pin in the end cap.

Alignment Pin Gerotor Assembly Outer Eccentric Ring Left Hand Rotation (Outside Looking Into Pump)

Outer Eccentric Ring Right Hand Rotation (Outside Looking Into Pump) 90000871

Orienting Gerotor Outer Ring and Alignment Pin (CCW Rotation)

9

NOTE: Do not mix charge pump piece parts from different production periods. Always install as a complete assembly.

Orienting Gerotor Outer Ring and Alignment Pin (CW Rotation)

1. Install the inner port plate and the gerotor assembly outer ring. 2. Install the alignment pin to properly orient the port plates and outer eccentric ring for corresponding pump rotation. 3. Prior to installation, apply a small quantity of petroleum jelly to the I.D., O.D., and side faces of the gerotor assembly to provide initial lubrication. 4. Install the gerotor assembly. 90000285

Install Inner Port Plate

90000286

5. Install the outer port plate (early production and intermediate production pumps only).

Install Gerotor Assembly Outer Ring

6. Install the spacer plate, if present (intermediate production pumps).

(continued)

90000287

Install Alignment Pin

90000289

Install Outer Port Plate (Early and Intermediate Production Only)

Pumps - Motors - Drives

90000288

Install Gerotor Assembly

90000290

Install Spacer Plate (Intermediate Production Only)

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7. Install the charge pump drive key into the charge pump shaft and retain with petroleum jelly.

NOTE: Intermediate production 75 cc and 100 cc pumps use the same charge pump drive shaft. Two keyways are provided in the drive shaft for the charge pumps used in these units. The rear keyway (with identifier groove) is used in 75 cc pumps. The front keyway (closest to the internally splined end of the shaft) is used in 100 cc pumps.

100 cc 75 cc

8. Install the charge pump shaft. The internally splined end of the shaft must engage the main pump shaft.

NOTE: The outside diameter of the internally splined end of some early production charge pump shafts was chamfered. Early production end caps may not be machined to accept a nonchamfered shaft. Always use a chamfered charge pump shaft in pumps with the early end cap.

90000291

Keyways in Charge Pump Shaft (Intermediate Production 075 and 100)

90000292

Install Charge Pump Shaft

9. For pumps with an auxiliary mounting pad, install the auxiliary drive coupling. 10. Install a new O-ring onto the non-auxiliary pad charge pump cover. (If an auxiliary pad is installed, an O-ring is not used on the cover.) 11. Carefully remove the alignment pin from the charge pump parts. Install the pin in its hole in the charge pump cover (see previous page for correct orientation) and retain with petroleum jelly. Install the cover (with alignment pin) into the end cap and aligned charge pump parts. (Take care not to damage the cover O-ring, if used.) CAUTION In order to avoid loss of charge pressure in pumps with an auxiliary mounting pad, always install the charge pump cover with the pad drain hole located on the same side of the end cap as the charge inlet port. Refer to Sec. 9.2.5 Auxiliary Pad Installation for details.

90000293

Aligning Pin Installed in Cover

90000294

Install Charge Pump Cover

12. Install the charge pump cover retainer and the six hex screws and torque the screws to 13.5 Nm (10 ft•lbf) for 030 through 100 pumps, and 32 Nm (24 ft•lbf) for 130 through 250 pumps. 13. For pumps with auxiliary mounting pads, install the O-ring and auxiliary mounting pad adaptor onto the end cap. Refer to Sec. 9.2.5 for instructions on auxiliary pad installation. 90000283

Install Cover Retainer

Pumps - Motors - Drives

122

90000295

Torque Retainer Screws

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Series 90

Minor Repair Instructions

9

9.2.5 Auxiliary Pad Installation 1. Using a 10 mm (030 through 100 pumps) or a 13 mm (130 through 250 pumps) hex wrench, remove the six screws holding the charge pump cover retainer. Remove the retainer. 2. Remove the charge pump cover and its O-ring.

NOTE: The original charge pump cover will not be used when installing the auxiliary pad. 3. Remove the four large screws which fasten the end cap to the pump housing. 90000282

90000284

Remove Screws and Retainer

Frame Size

Remove Charge Pump Cover

Hex Wrench Size Internal Hex

030 & 042 (early)

8 mm

042 (late)

10 m m

External Hex

055

19 m m

075 & 100

24 m m

100 & 130

14 m m

180 & 250

17 m m

NOTE: Late production pumps may not have the smaller screws installed to secure the end cap to the pump housing when the large screws are removed. On these pumps, secure the end cap to the pump housing with a clamp to avoid gasket damage.

90000296

Remove Large End Cap Screws

CAUTION Do not allow the force of the cylinder block spring and swashplate leveler springs to separate the end cap from the pump housing. Gasket damage and external leakage may result.

Charge Pump Parts

4. Take care to assure the surfaces are clean and free of any foreign material or paint prior to installing the auxiliary pad.

Cover Assembly Coupling (Typical) Journal Bearing

Special Washer

(continued)

End Cap Screw O-ring Auxiliary Pad (Typical) O-ring Pad Cover

Auxiliary Pad Kit

Cover Retainer Retainer Screw

Screw 90000876

Auxiliary Pad Components (Typical)

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5. Install the auxiliary drive coupling onto the pump drive shaft spline (auxiliary drive spline must be toward the rear of the pump). 6. Carefully remove the alignment pin from the charge pump parts. Install the pin in its hole in the new charge pump cover (with hole for the auxiliary coupling) and retain with petroleum jelly. Install the new charge pump cover with alignment pin into the end cap and the aligned charge pump parts. CAUTION In order to avoid loss of charge pressure, always install the charge pump cover with the pad drain hole located on the same side of the end cap as the charge inlet port.

90000297

Install Drive Coupling

90000298-

Install Alignment Pin in Cover (CCW Rotation shown)

7. Install the charge pump cover retainer and the six hex screws and torque the screws to 13.5 Nm (10 ft•lbf) for 030 through 100 pumps, and 32 Nm (24 ft•lbf) for 130 through 250 pumps. 8. Install O-ring on end cap pilot. 9. Install the auxiliary mounting pad adapter on external pilot on rear of end cap. 10. Install four new large screws and washers through the mounting pad and end cap into the housing. Torque per the accompanying table.

90000299

90000300

Install New Charge Pump Install Screws and Cover Cover Retainer

Torque

Frame Size

Wrench Size (Internal Hex)

Nm

lbf•ft

030 & 042 (early)

8 mm

75

55

042 (late) & 055

10 mm

122

90

075

14 mm

256

189

100 & 130

14 m m

298

220

180 & 250

17 m m

580

429

90000302

11. Install the O-ring and flange cover or auxiliary pump.

Install O-Ring on End Cap Pilot

90000303

Install Auxiliary Pad Adapter

Auxiliary Pad Conversion To convert an auxiliary mounting pad to a different size mounting pad, use the above procedure with the following additions: After removing the charge pump cover (step 2), remove the old auxiliary drive coupling. After removing the four end cap retaining screws (step 3), remove the old auxiliary mounting pad adapter.

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124

90000281

Install Auxiliary Pad Adapter Screws

90000305

Torque Pad Adapter Screws

22483 (01/04)

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A Terex Company

Series 90

Minor Repair

9

9.2.6 Filtration Options 9.2.6.1 Suction Filtration Installation 1. Install the hydraulic fitting to connect the external suction filter to the charge pump inlet port. 2. The reducer fitting (placed on the charge pressure gauge port) is installed as follows.

90000310

Charge Pump Inlet

90000243

Reducer Fitting

Torque

Frame Size

Wrench Siz e

042

1–1/4"

70 Nm

055 - 130

1–1/2"

122 Nm

[90 lbf•ft]

180 & 250

1–1/2"

156 Nm

[115 lbf•ft]

[52 lbf•ft]

The gauge port plug is torqued to 27 Nm (20 ft•lbf).

9.2.6.2 Remote Charge Pressure Filtration or Integral Charge Pressure Filtration Install either of these two filtration devices as follows. 1. Remove the reducer fitting, located at charge pressure gauge port, from pump end cap (this part will not be used). 90000311

Remote Pressure Filter Manifold

90000314

2. Install the filter manifold or filter head into the port. The hydraulic tube should enter its mating bore in the pump end cap with a low force.

Integral Pressure Filter Head

3. After rotating the filter manifold or filter head clockwise so that the threads engage with the threads in the end cap, continue to rotate it clockwise between 6 and 7 revolutions. Face manifold or head to the desired position.

90000312

Install Remote Pressure Filter Manifold

CAUTION Failure to install the filter manifold or filter head to a sufficient depth in the end cap will result in insufficient engagement of the tube in the end cap bore. This may allow unfiltered oil to bypass the filter and enter the charge system.

90000315

Install Integral Pressure Filter Head

4. While holding the filter manifold or filter head in the desired position, tighten the swivel lock nut.

90000313

90000316

Wrench Size

042

1–3/8"

70 Nm

055 - 130

1–5/8"

122 Nm

90 lbf•ft

180 & 250

1–5/8"

156 Nm

115 lbf•ft

Torque 52 lbf•ft

5. After installing the integral pressure filter head assembly, install the filter canister per the instructions on the filter canister.

Tighten Remote Pressure Tighten Integral Pressure Filter Manifold Lock Nut Filter Head Lock Nut

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9.3.5 Hydraulic and Electric Displacement Controls 1. Thoroughly clean external surfaces prior to removal of control. 2. Using a 5 mm internal hex wrench, remove the eight control mounting screws. Remove the control (with orifice check valve and spring) and control gasket from housing.

90000325

Remove Mounting Screws

CAUTION Protect exposed surfaces and cavities from damage and foreign material.

90000326

Remove Control

3. In preparation for installing the control, place a new gasket on the housing. Inspect to ensure that the control orifice check valve and spring are in their proper position in the control. 4. While setting the control into position, engage the pin on the control linkage into the mating hole in the link attached to the swashplate.

90000327

Inner Face of Control

5. With the control in position, move control assembly left and right to check engagement of pin in the link. Proper engagement will be indicated by an increasing resistance as the control is moved away from center position. Non-engagement of pin will be indicated by lack of spring force. In case of non-engagement, remove control and repeat the above procedure.

90000328

Assemble Control to Linkage

6. Align the control gasket and install the screws. Torque the screws to 16 Nm (12 ft•lbf).

NOTE: A sealing washer must be installed under the head of any mounting screws that are installed into "through" holes in the housing.

90000329

Install Mounting Screws

9.3.6 Pressure Control Pilot (PCP) for Electric Displacement Control

90000330

Torque Mounting Screws

1. Thoroughly clean external surfaces of control. 2. Using a 4 mm internal hex wrench, remove the four screws and remove the PCP. 3. Check surfaces for nicks or damage. Clean internal screens. 4. Install new O-rings in PCP Housing. Place PCP against EDC housing and install the screws. Torque to 5.4 Nm (48 in•lbf). 90000332

PCP Components

Pumps - Motors - Drives

NOTE: Do not remove black plastic cover from the aluminum plate. This is not a serviceable item and will void the product warranty.

90000334

Torque PCP Valve Screws

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9.3.7 3-Position (FNR) Electric Control 1. Thoroughly clean external surfaces prior to removal of control. 2. Using a 4 mm internal hex wrench, remove the four solenoid valve mounting screws. Remove the solenoid valve (with O-rings and orifice) from the adapter plate. 3. Using a 5 mm internal hex wrench, remove the eight adapter plate mounting screws. Remove the adapter plate and gasket from housing. CAUTION Protect exposed surfaces and cavities from damage and foreign material. 90000362

4. Inspect the orifice installed between the valve and adapter plate. This orifice MUST be installed in the case drain passage for proper pressure limiter operation.

3-Position Electric Control Components

5. In preparation for installing the adapter plate, place a new gasket on the housing. Place the adapter plate into position and install the screws. Torque the screws to 16 Nm (12 ft•lbf).

NOTE: A sealing washer must be installed under the head of any mounting screws that are installed into "thru" holes in the housing. 6. Install new O-rings and the orifice onto the solenoid valve assembly and install the solenoid valve onto the adapter plate. Install the screws and torque to 5.4 Nm (48 in•lbf).

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9.3.8 Displacement Control Components 9.3.8.1 Displacement Control Adapter Plate (Early Production 130 Pumps Only) The screws fastening the control adapter plate to the housing have retaining compound on the threads. They are removed with a 6 mm internal hex wrench. When installing the adapter plate, ensure the O-rings are in the proper position and torque the screws to 32 Nm (24 ft•lbf).

9.3.8.2 Displacement Control Filter Screens If the pump is equipped with control filter screens in the pump housing (late production), they should be pressed into position (with the rounded edge of the filter screens facing the control) until they are flush to 2.0 mm (0.08 inch) below the surface of the housing. 90000847

Displacement Control Adapter Plate (Early Production 130cc Pumps Only)

9.3.8.3 Displacement Control Orifice Check Valve TA

B

A

TB

1. Remove the control assembly as described in the instructions for the specific displacement control (9.3.2, 9.3.6, or 9.3.7). 2. The orifice check valve is located in the control assembly, at the surface of the pump housing face. Remove the spring retainer and spring from the orifice check valve cavity and then remove the orifice check valve.

P

Orifice Plugs

3. Install the desired orifice check valve in the cavity and then install the spring and spring retainer to hold the orifice check valve in position.

Orifice Check Valve 90000848

4. Assemble the control onto the pump. Refer to the instructions for the specific control (9.3.2, 9.3.6, or 9.3.7).

The Underside of an MDC Module Showing Orifice Locations A

9.3.8.4 Displacement Control Orifices

B TA

P

1. Remove the control assembly as described in the instructions for the specific displacement control (9.3.2, 9.3.6, or 9.3.7).

TB

2. Orifice plugs may be located in the control assembly, at the pump housing face surface. Remove the orifice plugs with a 4 mm internal hex wrench. Note the location of each plug, do not interchange plugs. Torque the orifice plugs to 3 Nm (32 in•lbf).

Orifice Plugs Orifice Check Valve 90000849

3. Assemble the control onto the pump. Refer to the instructions for the specific control.

The Underside of an HDC/EDC Module Showing Orifice Locations

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Exploded View Parts Drawings

10

10. Exploded View Parts Drawings 10.1 Variable Pumps 10.1.1 Name Plates

saue Ames, Iowa, U.S.A. Model Code

saue Neumünster, Germany Typ

Ames, Iowa, U.S.A. Model Code

90L055 EA 1 N 6 S 3 C6 C 03 HNN 35 35 24

Model Number

Model No.

Serial Number

90L055 EA 1 N 6 S 3 C6 C 03 HNN 35 35 24

Model Code Model Number

Ident Nr

94 – 2029 A – 88 – 26 – 67890

Model No.

Model Code

Ident Nr

687459 N – 88 – 26 – 67890

Serial Number

Serial No. Fabr Nr MADE IN U.S.A.

Neumünster, Germany Typ

Serial No. Fabr Nr MADE IN GERMANY

Place of Manufacture

Place of Manufacture

Name Plate (U.S.A. Production)

Name Plate (German Production)

90000860

10.1.2 Minor Repair Parts

K90 B83 OR B83

K10

B70 G532 G536

K50 K70

G542 G546 B82

K018 THRU K042

L35 (Early Production 075 Frame Size)

(L70)

(L40)

K80

L60

(B80)

(B90)

L30

P2B_ (B70) P30

L70

L40

B90

P06 P13

L50

P30 B71 P2A_

P06 P13

(K018 THRU K042)

G512 G516 G502 G506 G522 G526

G531 G538

G501 G508 G511 G518

G172 G176

B80 (G502 G506)

G541 G548

(G502 G506)

(G63) (G64)

G63 (CODE 61 OPTION)

G521 G528 (G501 G508) (G501 G508)

BOTH SIDES

Pumps - Motors - Drives

G63 (CODE 61 OPTION)

OR

G64 (CODE 61 OPTION)

129

(G63) (G64)

G64 (CODE 61 OPTION)

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Series 90

Exploded View Parts Drawings

10

10.1.3 Controls

M9ME

M0MA M0ME M0MB M0MF M0MC M0MG M0MD M0M9 M74M M78M

M76M

M0CA

OR M90D

M1DC M1DD

MODC MODD

M1CA M11C

M90C M87C

M92M M11D M97M M98M

M95M M96M

T001 THRU T009, T022 T050

OR M91E

M75M M72M M71M

M90M M1MA M880 M1MB M1MC M1MD M1ME M1MF M1MG

T201 THRU T209, T222 T250 T301 THRU T309, T322 T350

M0EA M0EF M0EP

M77M

T401 THRU T409, T422 T450

M7MA M7MB M7MC M7MD M7ME M7MF M7MG

M1HA, M1HC M1HF, M1HG M1HH, M1HJ M1HK, M1HL M1HM, M1HN M11H

M90H M880 M87H

M90E M1EA M880 M1EF M1EP

M9EA M9EP

M98E

M95E M97E M96E

M11E M87E

M87M M11M OR M870 M860 M850

OR M0HA, M0HC M0HF, M0HG M0HH, M0HJ M0HK, M0HL M0HM, M0HN

M840 M840 REF M830

S40 M810 M840 REF

M820

EARLY PRODUCTION 130CC PUMPS ONLY 90000861

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10

10.1.4 Filtration Options, Charge Pump Options, Auxiliary Pad Options

N40P

N40L

N00M N00S N35M REF

N35S N10S OR

N10M N30R

N35M

N00R

N25M

N20M N15M N31R

N10R

N20R N15R N25R

N35R

OR

90000862

H50L

H50 H40 H05

OR H30 H60 H50

H40 OR H05

H30

(H30) J80N

H40 H05

H60 H50

OR H60 H50 H90L

J40N J15N H70

J15_, J15L, OR J15R J10_

J30 J30

J70_

H80

H70

OR

J80_

J50_

J60_ J90_

H80 J00_, JL0_, OR JR0_

J92_

J95_

Pumps - Motors - Drives

131

90000863

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Exploded View Parts Drawings

10

10.1.5 Pump Parts List

Item

Description

Qty

B70 B71 B80 B82 B90

Plug Plug Plug Plug Control Filter Screen

2 1 1 1 3

G63 G64

Split Clamp Screw - Shipping Cover

4 4

G172 G176 G501 G502 G506 G508 G511 G512 G516 G518 G521 G522 G526 G528 G531 G532 G536 G538 G541 G542 G546 G548

Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug

1 1 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

H05B-H H05L H30 H40 H50 H60 H70 H80 H90L

Kit - Charge pump Spacer (No Charge pump) Port plate Pin Charge pump shaft Key Retaining plate Screw Plug

1 1 2 1 1 1 1 6 1

J00A J00B J00C J00D J00T J00V J00N J10A-V J15 J15N J30

Aux. mtg. ‘A’ flange Aux. mtg. ‘B’ flange Aux. mtg. ‘C’ flange Aux. mtg. ‘D’ flange Aux. mtg. ‘A’ flange (11T) Aux. mtg. ‘B-B flange Aux. mtg. flange - none Coupling Charge pump cover assembly Charge pump cover assembly Bushing

1 1 1 1 1 1 1 1 1 1 1

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132

Item

Description

Qty

J50A-V J60A/T J60B/V J60C J60D J70A-V J80A-V J80N J90A-V J92A-V J95A-V

O ring Flange adaptor Flange adaptor Flange adaptor Flange adaptor Washer Screw Screw O ring Cover plate Screw

1 1 1 1 1 4 4 4 1 1 2/4

K10 K50 K70 K80 K90

Plug Assembly O ring Spring Poppet Nut

1 1 1 1 1

L30 L35 L40 L50 L60 L70

Seal carrier Seal carrier Lip seal O ring Retainer Screw

1 1 1 1 1 3

L8 L9

Key Slotted nut

1 1

M0CA M1CA M11C M87C M90C

Control - Cover Plate Kit Cover plate Control gasket Washer, seal (042) Screw

1 1 1 1 6

M0DC M0DD M1DC M1DD M80 M87D M90D

Control kit 3 position FNR 12v Control kit 3 position FNR 24v Control 3 position FNR 12v Control 3 position FNR 24v Control gasket Washer, seal (042) Screw

1 1 1 1 1 1 6

M0EA M0EP M1EA M1EP M9EA M9EA M80 M87E M90E M91E M95E

EDC kit w/MS connector EDC kit w/Packard connector EDC w/MS connector EDC w/Packard connector PCP type 3 oil filled (MS) PCP type 3 oil filled (Packard) Control gasket Washer, seal (042) Screw Plastic cap (MS) O ring

1 1 1 1 1 1 1 1 6 1 2

22483 (01/04)

Technical Manual

A Terex Company

Series 90

Item

Exploded View Parts Drawings

Description

Qty

Item

Description

M810 M820 M830 M840 M850 M860 M870

Adapter Plate - Control (130 cc) O-ring (130 cc) O-ring (130 cc) O-ring (130 cc) Plug (130 cc) Screw (130 cc) Plug (130 cc)

1 1 1 2 1 6 1

N00M N10M N15M N20M N25M N30M N40L N40P

Filtration manifold kit (Int) Manifold O ring Nut Tube Plug Filter Filter

1 1 2 1 1 2 1 1

N00R N10R N15R N20R N25R N30R N00R

Filtration manifold kit (Rmt) Manifold O ring Nut Tube Plastic plug Plug

1 1 1 1 1 2 1

N00S N10S N30S

Filtration kit (Suction Flt) Reducer fitting (Suction Flt) Plug

1 1 1

P2A P2B P6 P13 P30

Multi-function valve assembly Multi-function valve assembly O ring O ring Plastic plug

1 1 2 2 2

T001-9 T201-9 T301-9 T401-9

Control orifice kit Orificed check valve Spring Spring retainer

1 1 1 1

M96E M97E M98E

O ring O ring Screw

1 1 4

M0HA M0HC M1HA M1HC M80 M87H M90H

HDC kit HDC kit HDC HDC Control gasket Washer, seal (042) Screw

1 1 1 1 1 1 6

M0MA M7M M71M M72M M80 M87M M90M

MDC w/o neutral start switch Control handle Washer Nut Control gasket Washer, seal (042) Screw

1 1 1 1 1 1 6

M0MB M7M M71M M72M M80 M87M M90M S40

MDC w/neutral start switch Control handle Washer Nut Control gasket Washer, seal (042) Screw Neutral start switch kit

1 1 1 1 1 1 6 1

M0MC M7M M71M M72M M74M M75M M77M M78M M80 M87M M90M

MDC w/sol. valve Control handle Washer Nut Solenoid valve Control manifold Manifold gasket Screw Control gasket Washer, seal (042) Screw

1 1 1 1 1 1 1 2 1 1 6

M0MD M7M M71M M72M M75M M76M M77M M78M M80 M87M M90M S40

MDC w/sol. valve, nss Control handle Washer Nut Control manifold Solenoid valve Manifold gasket Screw Control gasket Washer, seal (042) Screw Neutral start switch kit

1 1 1 1 1 1 1 2 1 1 6 1

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Vibrator Pump - S16 Rexroth All Grayhound Series Pavers

LH Rotation P/N 45080-003-39 Pump Mounted on back of Pump Stack

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RH Rotation P/N 45080-003-40 Pump Mounted on Engine

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Auxiliary Pump Eaton Model 70122 Piston Pump All Grayhound Series Pavers

This model pump is no longer available. Substitute with L-15 Sundstrand RH Rotation P/N 45080-002-48 Pump Mounted on Engine

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LH Rotation P/N 45080-002-49 Pump Mounted on back of Pump Stack

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Auxiliary Pump L-15 Sundstrand All Grayhound Series Pavers

The Following Pages are Portions of Manual Form 19543 Sunstrand Sauer L15 Open Circuit Pump Service and Repair Manual All Grayhound Pavers

Auxiliary Pump 45080-002-10 45080-002-24

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Maintenance Information Fluids Hydraulic fluids used with Sauer-Sundstrand products should be carefully selected with assistance from a reputable supplier following the guidelines presented in the "Hydraulics Fluid Requirements" bulletin BLN-9987.

Incorrect alignment may result in eventual damage to the drive shaft, drive shaft bearings, or the drive shaft seal which can cause external oil leakage. Start Up Procedure Fill the reservoir with recommended hydraulic fluid which should be passed through a 25 micron (nominal) filter prior to entering the reservoir. Never reuse fluid.

The following types of fluids have been used successfully in Sauer-Sundstrand hydrostatic products: 1)Anti wear hydraulic oil. 2)Type F Automatic Transmission Fluid. 3)Engine oils meeting the requirements of API classification CD. 4)Hydraulic transmission fluid of the type used by the agricultural industry for combined transmission, hydraulic and wet brake system. The fluid selected should provide a viscosity between 150 and 275 SSU at 100°F.

The inlet line leading from the pump to the reservoir must be filled prior to start-up. Check inlet line for properly tightened fittings and be certain it is free of restrictions and air leaks. Be certain to fill the main pump housing with clean hydraulic fluid prior to start up. Fill main pump housing by pouring the filtered oil in the upper most case drain hole. Caution! Operation of the pump with less than 160 PSI discharge pressure may reduce the life of the unit.

Caution! As with any hydraulic system, a key to successful operation and predicted life is cleanliness of the various components and the fluid. Strict compliance with component cleanliness recommendations and fluid filtration requirements are a must. Failure to follow such recommendations and requirements can result in excessive pump flow loss and control valve malfunctions that can render an complete system inoperative or even cause catastrophic failure.

See machine operating manual for machine start-up procedures. On mobile applications, run at the lowest possible speed, with a minimum of 160 PSI until system pressure has been established. Once system pressure is positive, increase the speed to full RPM. On electric motor drives jog the motor several times before initial start-up. In both cases if system pressure is not maintained, shut down the system and determine cause.

Installation Prior to installing the pump, inspect for damage during shipment and handling. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid.

The hydraulic system should be operated for at least fifteen (15) minutes under light load conditions. Shut down the system and remove the pressure gauge. Check fluid level in the reservoir and add fluid if necessary.

The pump should be connected to the prime mover so that the centers of both drive shafts are aligned.

Pumps - Motors - Drives

The pump is now ready for operation.

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Maintenance Information System Maintenance For satisfactory service, regular maintenance of fluid and filters must be performed. Check fluid level daily. Change fluid more often if it becomes contaminated with any foreign matter (dirt, water, grease, etc.) Change Inlet and Return filter whenever fluid is changed and whenever filter indicator shows a change is necessary. Replace all fluid lost during filter change.

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Troubleshooting Troubleshooting The information contained in this section provides a guide for troubleshooting Sauer-Sundstrand Series L pumps. It is a problem solving tool aimed at reducing unnecessary machine downtime. Following the fault-logic approach will assist in the expedient correction of system problems.

SYSTEM PRESSURE (TEE 5,000 OR 10,000 PSI GAUGE INTO OUTLET HOSE) INLET VACUUM (TEE VACUUM GAUGE INTO INLET HOSE)

CASE DRAIN (CASE PRESSURE)

Various pressure and vacuum gauge readings can be a great asset in troubleshooting problems with the pump or support system.

INLET

It will be necessary to tee a high pressure gauge into the system pressure line to check the setting of the system relief valve as well as control settings.

RESERVOIR INLET SCREEN

Measuring the inlet pressure will help locate restrictions in the inlet lines, filter, etc. Note: Snubbers are recommended to protect gauges. Gauge calibration is also necessary to insure accuracy of readings.

A. EXCESSIVE NOISE AND/OR VIBRATION CHECK OIL LEVEL IN RESERVOIR

OK

AIR IN SYSTEM

OK

CHECK PUMP INLET PRESSURE

OK

INSPECT SHAFT COUPLING

OK

INSPECT SHAFT ALIGNMENT

LOW

LOOSE FITTING IN SUCTION LINE OR RETURN LINE

DEFECTIVE

DEFECTIVE

DEFECTIVE

FILL TO PROPER LEVEL

PURGE AIR AND TIGHTEN FITTING

CORRECT

REPAIR OR REPLACE

ALIGN SHAFTS

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Troubleshooting B. SYSTEM OPERATING HOT CHECK OIL LEVEL IN RESERVOIR

OK

INSPECT HEAT EXCHANGER

LOW

OK

DEFECTIVE

FILL TO PROPER LEVEL

OK

CHECK PUMP INLET PRESSURE

LOW (SEE NOTE 1)

LOW

CHECK SYSTEM RELIEF VALVE SETTING

REPAIR OR REPLACE

ADJUST SETTING

OK

CHECK CONTROL VALVE

OK

SEE NOTE 2

CORRECT (REFER TO F)

REPAIR

CHECK FOR INTERNAL SYSTEM LEAKS

1)If System Relief Valve is set below the Pressure Compensator control, the valve can open prematurely and result in heat buildup. The relief valve should be set at least 300 PSI above desired pressure compensator setting. 2)In the same manner, if the compensator is inoperable the relief valve will open in response to excessive pressure and create heat in the system.

HIGH

REPAIR AS REQUIRED

C. SYSTEM RESPONSE IS SLUGGISH

CHECK SYSTEM RELIEF VALVE SETTING

LOW

ADJUST SETTING

Pumps - Motors - Drives

OK

CHECK CONTROL SETTING

OK

INCORRECT

ADJUST SETTING

CHECK CONTROL SIGNAL PRESSURES

OK

DEFECTIVE CONTROL

INCORRECT

REPAIR

140

OK

INTERNAL SYSTEM LEAKS

HIGH LEAKAGE

REPLACE CONTROL (REFER TO E)

REPAIR AS NEEDED

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Troubleshooting D. LOW PUMP OUTPUT FLOW CHECK OIL LEVEL IN RESERVOIR

OK

LOW

CHECK SYSTEM RELIEF VALVE SETTING

OK

LOW

FILL TO PROPER LEVEL

ADJUST SETTING

OK

CHECK PUMP INLET PRESSURE

INCORRECT

LOW

CHECK PUMP CONTROL SETTING

ADJUST SETTING

OK

CHECK INPUT SPEED

OK

LOW

CORRECT (REFER TO F)

CORRECT

CHECK MAXIMUM FLOW ADJUSTMENT

INCORRECT

ADJUST SETTING

E. COMPENSATOR VALVE DOES NOT OPERATE

CHECK CONTROL SETTING

OK

INSPECT COMPENSATOR SPRING

INCORRECT

WRONG PRESSURE RANGE

ADJUST SETTING

REPLACE

Pumps - Motors - Drives

OK

INSPECT FOR LEAKAGE

CORRECT

141

OK

INSPECT COMPENSATOR SPOOL

OK

INSPECT FLOW CONTROL CYLINDER

DAMAGED OR CONTAMINATED

DAMAGED OR CONTAMINATED

REPAIR OR REPLACE

REPAIR OR REPLACE

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Troubleshooting

F. HIGH INLET VACCUM

CHECK OIL TEMPERATURE

OK

INSPECT INLET FILTER

OK

CHECK OIL VISCOSITY

OK

INSPECT INLET PIPING

COLD

CLOGGED OR TOO SMALL OF MESH

ABOVE 150-275 SSU AT 100 F

TOO LONG OR SMALL DIAMETER

ALLOW SYSTEM TO WARM UP

REPLACE FILTER

REPLACE OIL

REPAIR

AFFECTED PART

PROBLEM

PROBABLE CAUSE A. Pump is used at higher than maximum working pressure B. Seizure is due to lack of lubrication

Broken Shaft

Needle bearing wear on L-15 Excessive shaft end play on L23, L38, L50, L70 models

Wear

Seizure

A. Oil contamination

Wear

A. B. C. D. E.

Slipper Pads

Wear

A. Oil contamination B. Excessive speed C. Excessive pressure

Bearings

Damage

A. Improper shaft alignment B. Abnormal pressure C. Insufficient end play on L23, L38, L50 and L70 models

Oil Seals

Damage

A. Excessive case leakage B. Excessive case pressure C. Improper shaft alignment

Control Cylinder Cylinder Rod

Wear

Cylinder Block Valve Plate

Excessive oil temperature Cavitation Improper case drain filling Excessive speed Excessive pressure

A. Oil contamination

Common Causes of Wear and Part Damage

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Standard Control Adjustment Maximum Flow Adjustment Maximum volume or flow from the pump can be varied to match the application requirement by turning the flow adjusting screw located on the back of the pump.

DISPLACEMENT

COUNTERCLOCKWISE TURNING

CLOCKWISE TURNING

Using appropriate wrenches, loosen the locknut and turn the adjusting screw clockwise to decrease maximum pump flow or counterclockwise to increase maximum flow.

PRESSURE

FLOW ADJUSTING SCREW

The flow rate will be increased or decreased by approximately the following amount for each complete turn of the adjustment screw.

END CAP CYLINDER ROD CONTROL CYINDER

L15 .091 in. 3/rev. per turn

COUNTERCLOCKWISE TURNING

CLOCKWISE TURNING

L23 .123 in. 3/rev. per turn L38 .15 in. 3/rev. per turn CAP

L50 .25 in 3/rev. per turn

SWASHPLATE

L70 .31 in. 3/rev. per turn

Stops are provided to limit both the minium and maximum positions of the screw within the following angle and displacement per revolution range. PUMP SIZE

SWASHPLATE ANGLE

L15

2° to 15°

3 3 0.135 in. /rev. to 0.913 in. /rev.

L23

5° to 17°

3 3 0.378 in. /rev. to 1.41 in. /rev.

L38

7° to 18°

3 3 0.9 in. /rev. to 2.3 in. /rev.

L50

0° to 18°

3 0 to 3.15 in. /rev.

L70

2° to 18°

DISPLACEMENT

.4 in. 3/rev. to 4.26 in. 3/rev.

Flow Adjustment

After adjustment, hold the screw in place and torque the locknut to 12-16 ft. lbs. Caution! Excessive torque may damage threads and allow setting to change during operation.

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Pressure Compensator Control (PC) The following adjustment procedure is applicable for the pressure compensator function on the pressure compensator control, the flow and pressure compensator control and the remote pressure compensator control.

CLOCKWISE TURNING

COUNTERCLOCKWISE TURNING

DISPLACEMENT

Standard Control Adjustment

The standard pressure compensator adjustment range is 500 to 3000 PSI (35 BAR to 210 BAR). The following optional ranges are available. 250-1000 PSI (15 BAR to 70 BAR) and 250-2000 PSI (15 BAR to 140 BAR)

PRESSURE

Typical Pressure Compensator Curve

LOCKNUT P

It is necessary to refer to the machine specifications for specific control settings and any procedures particular to adjusting the control on each machine.

PRESSURE ADJUSTING SPRING SCREW

P

1)The system relief valve should be set at least 300 PSI (20 BAR) higher than the desired pressure compensator setting. 2)The flow compensator function, if present, must be disabled prior to adjusting the pressure compensator by connecting system pressure to the flow compensator feedback port. 3)Using an appropriate adapter, connect a high pressure gauge (10,000 PSI) into the pressure line from the pump. Warning! To set the pressure compensator requires deadheading the pump. Take necessary precautions of securing the work function so no movement of the load occurs, and also that the system high pressure relief valve is properly adjusted as noted earlier.

COUNTERCLOCKWISE TURNING

VALVE BODY

CLOCKWISE TURNING

SPOOL

Cutaway View of Pressure Compensator Control

SYSTEM PRESSURE CONTROL SETTING DIRECTIONAL VALVE IN CLOSED POSITION

PRESS. COMP

PV TO SYSTEM

SYSTEM RELIEF VALVE SET 300 PSI ABLVE CONTROL SETTING

4)Start the prime mover and allow fluid to reach normal operating temperature. 5)Note the high pressure gauge reading which is the pressure setting of the pressure compensator. Refer to machine specifications for proper pressure setting. 6)To adjust the pressure compensator loosen the locknut. Then, using appropriate hex wrench, turn the adjusting screw clockwise to increase setting or counterclockwise to decrease setting.

Typical System Schematic Using Pressure Compensator Control

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Standard Control Adjustment If the pressure setting does not increase in response to turning the adjustment screw clockwise, the system relief valve may be improperly adjusted. 7)Once the desired pressure setting (shown on the pressure gauge) is obtained, hold the adjustment screw in place and torque the locknut to 16-20 ft. lbs. Note: Cycle pump 2 or 3 times to insure pressure setting is maintained. Pressure Adjustment on the Flow Pressure Control

L50 & L70

L15, L23 & L38 3000

210

3000

PR

G

175

70

00

G

N RI

00

I PS

105

SP

20

70

1000 0 100

PS

I

R SP

ING

30

PS

2000

COMPENSATING PRESSURE

105

140

00

140

30

COMPENSATING PRESSURE

IS

PS

PR

IS

IN

175

IN

G

210

2000

G

IN

I

PS

0 00

R SP

2

1000

NG

PRI

0

100

S PSI

35

35 0

0 PSI

BAR

0

1

2

3

PSI

BAR

0

1

2

3

4

PRESSURE ADJUSTING SCREW (REVOLUTIONS)

4

PRESSURE ADJUSTING SCREW (REVOLUTIONS)

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Minor Repairs Introduction The areas of repair indicated are classified as minor repairs and may be performed, following the procedures in the section, without voiding the unit warranty. Although specific units are illustrated, these procedures apply to all series and types of units in the Series L Family. General Cleanliness is a primary means of insuring satisfactory pump life, on either new or repaired units. Cleaning parts by using a solvent wash and air drying is adequate, providing clean solvent is used. As with any precision equipment, the internal mechanism and related items must be kept free of foreign materials and chemicals.

Removal of a Standard Control

Protect all exposed sealing surfaces and open cavities from damage and foreign material. It is recommended that all gaskets and o-rings be replaced. All gasket sealing surfaces must be cleaned prior to installing a new gasket. Lightly lubricate all o-rings with clean petroleum jelly prior to assembly.

L15, L50, L70 Style Shown

L15, L50, L70 Models

Shaft Seal Removal Two types of shaft seals are used on the L Series pumps. The L15, L50 and L70 models each utilize a seal retainer and O-ring. The L23 and L38 models, however, use a replaceable seal and retaining ring only. Refer to the appropriate instruction which follow for seal replacement. Please note: The seal retainer on the L50 manufactured after serial number 84-50XXXX has been eliminated.

L23 and L38 Models

Using retaining ring pliers, remove the retaining ring from the shaft end of the pump. Caution! The retaining ring holds the shaft in the housing on the L15 model. Do not pull on the shaft after the retaining ring has been removed. In the event the shaft is pulled from the housing, do no attempt to slide it back into the unit. The shaft aligns all cylinder block components, which have

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Minor Repairs probably now become misaligned. Reinstalling the shaft by sliding it back in will damage the cylinder block assembly. Once the shaft has been removed, it becomes necessary to remove the end cap and cylinder block. Refer to the major repair section of this manual. L15, L50 and L70 Models Install a screw into each of the two threaded holes in the face of the seal retainer. (The screws which hold the control onto the end cap will fit.) Pull or pry the seal retainer from the housing. The retainer will not come out easily as it is held in place by a large o-ring. Using a seal driver or similar tool, remove the seal from the seal retainer. Discard the seal when removed. Remove and discard the o-ring from the outside of the seal retainer. L23 and L38 Models Using a punch, or some type of sharp instrument, puncture the shaft seal and gently pry it out of the housing. Remove the old seal from the shaft and discard. Installation L15, L50 and L70 Models Use a seal driver or similar tool to press a new seal into the seal retainer. Make certain the seal is bottomed on the counterbore within the retainer. Caution! Do not use excessive force as seal will be damaged. Install a new o-ring on the outside of the seal retainer. Lubricate the o-ring with oil and slide the seal retainer over the shaft and into the housing. Press the seal retainer into the housing until the retaining ring groove is exposed. Install the retaining ring with the beveled side out. Make certain the retaining ring has snapped into the groove completely.

Standard Control Removal

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Minor Repairs L23 and L38 Models Lubricate the new seal with oil and carefully slide it over the shaft. Make sure the shaft is covered or other measures have been taken to protect the seal from damage by the shaft keyway. Press the seal into place and securely install the retaining ring in the groove within the housing. Control Using an internal hex wrench, remove the four socket head screws which hold the control on the end cap. Remove the control and gasket from the end cap. Remove the o-ring from the groove in the mating surface of the control.

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Minor Repairs It is suggested that a new o-ring be installed on the control and a new gasket placed on the end cap mating surface. Make certain the large hole on the gasket will mate with the o-ring on the control when assembled. Place the control on the end cap and reinstall mounting screws. Tighten to 61-69 in. lbs. torque. Note: The standard controls, which include the pressure compensator, remote pressure compensator and flow and pressure compensator controls, for the L15, L23 and L38 are interchangeable between the three models. Likewise, the standard controls are interchangeable between the L50 and L70 models. All other controls are not interchangeable.

Note orientation of gasket with relation to O-ring

SPRING RETAINER SPOOL

SPRING

ADJUSTMENT

END PLUG

LOCKNUT

Standard Control Disassembly If the control is not performing properly because of a sticking or contamination, it can be further disassembled for cleaning or repair. Using appropriate wrenches, loosen the adjustment screw locknut and remove the adjustment screw. The control spring and spring retainer can now be removed from the cavity. Using an internal hex wrench remove the threaded plug from the opposite end of the control and remove the control spool.

When reassembling control, be sure spool is not reversed

Remote Pressure Compensator Control Flow and Pressure Compensator Control Pressure Compensator Control

{ { {

Flush the control cavity with clean solvent and wash all parts in solvent and air dry. Examine spool and cavity surfaces for nicks or scratches and replace any parts found to be defective.

Pressure Compensator Adjustment Flow Compensator Adjustment

Replace spring and spring retainer in cavity from adjustment end and reinstall adjustment screw and locknut. Install control spool in opposite end of control and install plug. Insure that orientation of spool is correct.

Pressure Compensator Adjustment

Exploded View of Standard Control

Reinstall control on pump housing replacing o-ring and control gasket as part of the procedure. Refer to control adjustment procedure in this manual and set control for maximum system pressure.

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Fastach II Generator Drive Pump Rexroth A10VO All Grayhound Series Pavers

Max Pressure Valve

Standby Pressure Valve

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Fastach II Generator Drive Pump Set-Up Procedure All Grayhound Pavers

Screed Generator Pump Set-Up To properly operate the Fastach II screed electric heating units, it is necessary to set up the screed generator pump circuit. This hydraulic pump circuit has three (3) valves which require adjustment, the

needle valve (located on the drive motor manifold), and the pump standby and max pressure valves (both located on the pump) (Figure 1).

Generator Drive Motor

Generator Control Box

Generator Pump (Mounted on Tractor)

Motor Manifold

Needle Valve

Standby Pressure Valve

Test Port (P)

Max Pressure Valve

Figure 1 Screed Generator Hydraulic Pump Adjustments

Start-up After Initial Installation of Pump

5) Turn generator switch on and let run with engine at idle approximately one (1) minute to prime pump and purge air from lines. Generator should turn at a low speed.

1) Fill pump housing with clean oil. Do this through the case drain port on the pump housing.

Notice - Do not apply electrical load to generator.

2) Loosen needle valve jam nut on screed generator drive motor manifold.

6) Turn generator switch off. 3) Turn screw clockwise until it bottoms to fully close valve.

7) Shut off engine.

4) Start engine and run at idle.

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Fastach II Generator Drive Pump Set-Up Procedure All Grayhound Pavers Set Pump Max Pressure

4) Re-start engine and run at 1400 rpm.

1) Start engine and run at 1400 rpm.

5) Re-check pressure to make sure standby pressure reads 400 psi. Adjust if necessary.

Notice - Make sure generator switch is turned OFF.

6) Tighten jam nut on standby pressure adjustment screw and reinstall cap.

2) Install 6000 psi gauge on test port (P) of generator drive motor manifold. (Figure 1)

7) Shut off engine. Set Generator Motor Speed (Frequency) 1) Install a frequency (Hz) test meter into the 120 volt outlet on the generator control box. (Figure 2)

3) Remove cap from standby pressure adjustment screw and loosen jam nut. 4) Turn standby pressure adjustment screw clockwise until it bottoms to fully seat valve.

2) Start engine and run at 1400 rpm. 5) Note gauge pressure: Pressure will be approximately 500 - 2500 psi.

3) Turn generator switch on.

6) Remove cap from max pressure adjustment screw and loosen jam nut.

4) Turn needle valve screw counter-clockwise until test meter reads 62 Hz.

7) Turn max pressure adjustment screw clockwise until gauge reads 4000 psi.

5) Tighten jam nut on needle valve. 6) Shut off engine.

8) Tighten jam nut on max pressure adjustment screw and reinstall cap. Set Pump Standby Pressure 1) With engine still running at 1400 rpm as described above, turn standby pressure adjustment screw counter-clockwise until gauge reads approximately 400 psi. Notice - Make sure generator switch is turned OFF. Figure 2 Setting Generator Frequency

2) Shut off engine.

Screed generator pump and hydraulics are now ready to be put into operation.

3) Remove 6000 psi gauge and install 1000 psi gauge.

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Stretch Electric Screed Generator Drive Pump Set-Up Procedure All Grayhound & Tier II Pavers

Screed Generator Pump Set-Up Generator Pump (Mounted on Tractor)

Generator Drive Motor

PC Cartridge Valve Pressure Adjustment (4000 psi)

Motor Manifold Needle Valve

Standby Pressure Adjustment Screw (400 psi)

Test Port (P)

Figure 3 Screed Generator Hydraulic Pump Assembly

To properly operate the screed electric heating units, it is necessary to set up the screed generator pump circuit.

drive motor manifold. 3)

This hydraulic pump circuit has three valves which require adjustment: the needle valve (located on the drive motor manifold), the pump standby pressure adjustment screw and the maximum pressure valves, both located on the pump (Figure 3).

Turn screw clockwise until it bottoms to fully close valve.

4) Start engine and run at idle. 5) Turn generator switch on and let run with engine at idle approximately one (1) minute to prime pump and purge air from lines. Generator should turn at a low speed.

Start-up After Initial Installation of Pump 1) Fill pump housing with clean oil. Do this through the case drain port on the pump housing.

CAUTION

2) Loosen needle valve jam nut on screed generator

Do not apply electrical load to generator. 6) Turn generator switch off. 7) Shut off engine.

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Stretch Electric Screed Generator Drive Pump Set-Up Procedure All Grayhound & Tier II Pavers Set Pump Max Pressure

NOTICE Make sure generator switch is turned OFF or the screed is disconnected from the tractor. 1)

Install 6000 psi gauge on test port (P) of generator drive motor manifold (Figure 3 ).

X Port (Not Shown)

M2 Port

2) Remove load sensor line from X port on pump. (Figure 4 ). Connect M2 and X Ports With Jumper Hose Figure 5 M2 Port - Tractor Generator Pump

5) Loosen the jam nut on the max pressure adjustment screw. 6) Turn max pressure adjustment screw clockwise until gauge reads 4000 psi. 7) Tighten jam nut on max pressure adjustment screw. 8) Shut off engine. X Port

9) Remove jumper hose and reconnect load sensor line to the X port on pump.

Figure 4 X Port - Tractor Generator Pump

Set Pump Standby Pressure Add a jumper hose between ports X and M2 on 1) Start engine and run at 1400 rpm as described above. Turn standby pressure adjustment screw pump (Figure 5 ). counter-clockwise until gauge reads approximately 400 psi. 4) Start engine and run at 1400 rpm. 3)

NOTICE Make sure generator switch is turned OFF.

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Stretch Electric Screed Generator Drive Pump Set-Up Procedure All Grayhound & Tier II Pavers The screed generator pump and hydraulics are now ready to be put into operation.

2) Shut off engine. 3) Remove 6000 psi gauge and install 1000 psi gauge.

Tractor Generator Plumbing Adding or removing the electric screed from the tractor will require changes to the tractor generator pump plumbing configuration.

4) Re-start engine and run at 1400 rpm. 5) Re-check pressure to make sure standby pressure reads 400 psi. Adjust if necessary.

CAUTION

6) Tighten jam nut on standby pressure adjustment screw and reinstall cap.

Make sure generator pump plumbing is properly connected prior to operation.

7) Shut off engine. Set Generator Motor Speed (Frequency)

Attaching Screed To Tractor Generator Pump

1) Install a frequency (Hz) test meter into the 120-volt outlet on the generator control box (Figure 6).

When the screed is attached to the tractor, the generator pump load sensor line is connected to the quick connect fitting on the screed’s generator drive hydraulic motor (Figure 7).

2) Start engine and run at 1400 rpm. 3) Turn generator switch on. 4) Turn needle valve screw counter-clockwise until test meter reads 62 Hz. 5) Tighten jam nut on needle valve. 6) Shut off engine.

Connect Load Sensor Line From Pump To Valve

Figure 7 Tractor Generator Pump Connection on Screed Generator Drive Motor

Figure 6 Setting Generator Frequency Pumps - Motors - Drives

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Stretch Electric Screed Generator Drive Pump Set-Up Procedure All Grayhound & Tier II Pavers Operating Tractor Pump Without Screed Removing the screed from tractor requires disconnecting the generator pump load sensor line from the screed’s generator drive motor. The line is then rerouted to the pump by attaching it to the 1/ 4" nipple on the rear of the tractor (Figure 8).

RH Conveyor Motor

Coupling

Figure 8 Generator Pump Connections for Detached Screed

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Conveyor Drive Motor Char-Lynn 6000 Series All Grayhound Series Pavers

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Lohmann & Stolterfoht Travel Drive Unit Assembly All Grayhound Series Pavers

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Travel Drive Motor Rexroth (Various Series) All Grayhound Series Pavers

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Travel Drive Motor Begin of Stroke Adjustment Procedure All Grayhound Series Pavers Description

Tire and steel track units are set by the motor supplier and adjustment should not be necessary unless a problem is encountered.

The begin of stroke adjustment on the travel motors is required to assure proper automatic shift operation when paver is in “Travel Mode”. It is important that both travel motors shift from “Travel” to “Pave” at the same pressure. Tire and steel track units are set at 2500 psi. Rubber track units are set at 4400 psi.

Rubber track units must be adjusted to match the two sides. This must be done when one or both travel motors are replaced or when a problem is encountered.

Figure 1 Travel Motor Port Location

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Travel Drive Motor Begin of Stroke Adjustment Procedure All Grayhound Series Pavers Preparation for Adjustment 1) Isolate each side G ports by disconnecting the cross-over line at left side motor bulkhead (tire units will require removal of tire) or, on rubber track, left side take-up valve (400 & 500 series).

DIN Connector

2) Install 10,000 psi gauge on each side G port at the point you disconnected above. 3) Install 10,000 psi gauge on each side M1 test port.

Figure 4 Brake Valve DIN Connector 300 Series

4) Raise hood, lock in up position, and set brakes by removing DIN connector from brake solenoid valve.(Figure 4 or Figure 5)

DIN Connector

Figure 5 Brake Valve DIN Connector 400/500 Series

5) Raise paver frame, lock screed in up position, and jack up paver and block to access the underneath side of travel motors.

Figure 2 Gauges Installed 300 Series Rubber Track Shown

You may now proceed with the adjustment procedure. Begin of Stroke Adjustment Procedure 1) Start and run engine at idle. 2) Travel switch in FORWARD, speed dial at “0”, range switch in TRAVEL, and steering wheel centered. Figure 3 400/500 Rubber Track Units Pumps - Motors - Drives

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Travel Drive Motor Begin of Stroke Adjustment Procedure All Grayhound Series Pavers 3) Slowly increase travel speed dial and note what each G port pressure gauge reads at the point each side begins to shift to pave speed. (Figure 6)

Figure 7 Begin of Stroke Adjustment

6) To change the setting turn the adjustment screw in (clockwise) to lower the begin point setting and out (counter clockwise) to increase the begin point setting. Figure 6 Pressure Readings

7) Repeat steps 1 through 6 until the required begin of stroke set point is achieved, stable, and the same on each side.

The G port pressure should rise steadily while the M1 port pressure will rise just a little, remain steady, then start continuing to rise as the dial is turned. Read G port pressure when M1 port pressure starts rising again. This is the Begin of Stroke Point.

8) After obtaining the desired setting, lock begin of stroke adjustment screw into place. 9) Shut down engine.

Caution - Do not allow oil to flow over the high pressure relief valves for long periods of time, as excessive heat can be generated to the pump.

10) Remove individual gauges from G ports and tee one 10,000 psi gauge in G port cross-over line.

4) Note: The begin of stroke setting should be 2500 psi for tire and steel track units and 4400 psi for rubber track units.

Caution - Port G may contain trapped pressure.

5) Break off the tamper resistant cap on the HA control valve adjustment screw and back off the locknut while holding the adjustment screw with a 3mm hex wrench. The locknut requires a 10mm wrench. (Figure 7)

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Travel Drive Motor Begin of Stroke Adjustment Procedure All Grayhound Series Pavers 11) Repeat steps 1 through 6 again to verify proper shifting. 12) Perform above adjustment until proper shifting is achieved. 13) Shut down engine. Caution - Port G may contain trapped pressure.

14) Remove all gauges and reconnect crossover line on G ports.

Figure 8 Rubber Tire Units

The following figures show the bulkhead areas for the rubber tire units (Figure 8) and steel track units (Figure 9). As you may note, there are no gauge fittings pre-installed on these units. You must remove the hoses/lines and install gauge fittings to perform the above mentioned procedure.

Figure 9 Steel Track Units

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Travel Drive Motor Self-cleaning Swivel-time Orifices All Grayhound Series Pavers

Orifice Plug " B"

Uni-Directional Shuttle Orifice

Orifice Plug " A"

Passage 1

Passage 2

Bi-Directional Shuttle Orifice "M 1" Port Motor Cap

There are two types of self-cleaning swivel-time orifices available, a uni-directional and a bi-directional. This means that one type of shuttle orifice will control flow in one direction and will free flow in the other. The second type of shuttle orifice will control flow in both directions. Both types of shuttle orifices are shown above. A swivel-time orifice kit is made up of two orifice plugs and one shuttle orifice. This kit is inserted into the "M1" port of the motor cap (see page 26 for "M1" port location). There is only one way to properly insert the swivel-time kit. First, thread orifice plug "A" into the "M1" port until it bottoms. Caution: Do not overtighten this orifice plug. Next, insert the shuttle orifice in it's proper orientation for desired flow control. Finally, thread orifice plug "B" into the "M1" port until it is tightly against orifice plug "A". Plug port "M1".

Pumps - Motors - Drives

The bi-directional shuttle orifice can be inserted with either tapered end in first. It's orientation does not affect flow control. The orientation of the uni-directional shuttle is important. With the uni-directional shuttle assembled into the motor cap as shown above, controlled flow will be from passage 2 to passage 1 (into the stroking piston). Free flow will occur from passage 1 to passage 2 (out of the stroking piston). To reverse flow control, rotate the uni-directional shuttle orifice 180˚. The orifice plug “B” requires a 5mm Allen Wrench and orifice plug “A” requires a 6mm Allen Wrench. Note: When using a uni-directional shuttle orifice, it will typically be assembled to control motor swivel time from minimum to maximum displacement. Contact Rexroth for more details.

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Travel Drive Motor Installation, Start-up, & Troubleshooting All Grayhound Series Pavers Installation The AA6VM motor may be mounted in any position. When mounting in a shaft up position, special considerations regarding the case drain line may be required to ensure the motor bearings are always immersed in oil. The AA6VM is usually face mounted to a final drive gear box with the shaft engaging a mating female splined gear hub or spline adapter. The large drive shaft bearings permit vee or toothed belt pulleys, or gear pinions to be mounted directly to the drive shaft. (Consult Rexroth for radial and axial force limitations.) The motor may also be used to transmit power via a universal drive shaft. The case drain line should be connected to the highest case drain port so that the motor always remains full of oil. For mobile applications, the oil reservoir capacity required (in U.S. gallons) is generally .75 to 1 times the charge pump flow (in U.S. gallons per minute) for a one pump, one motor transmission. The heat exchanger should be located between the pump case drain and the reservoir, and sized to accept the full flow of the charge pump at the maximum anticipated drive speed. To accommodate slight shaft misalignment and to dampen vibration, use of a flexible coupling is recommended. The motor user should work closely with the coupling manufacturer in selecting and applying a suitable coupling . When flexible couplings, Veebelts or toothed timing belts are to be used, the coupling halve, gear or pulley, should be secured to the drive shaft using a spacer between the coupling and the shoulder on the drive shaft, and locking the coupling to the shaft by using a set screw into the threaded hole in the end of the shaft. If this is not possible, as when mounting the motor to a drive gearbox, Optimoly Paste White T multipurpose lubricating paste or equivalent must be applied to the shaft to avoid fretting corrosion of the spline.

Motor Flushing A flushing valve is usually required when a motor will be operated for extended periods of time at high speed and/or high pressure conditions.

Each application should be analyzed to determine the proper method of filtration needed to maintain the required cleanliness levels, as contaminant generation and ingression can vary greatly,depending on the configuration and complexity of the system. For particular system requirement, or for application outside these parameters, a Rexroth Applications Engineer should be consulted. Pre-Start Procedure This should be performed prior to start-up a new installation, or for a system in which new or overhauled components have been fitted. 1. Ensure that hydraulic reservoir piping and pressure hoses are cleaned and flushed. 2. Fill the reservoir through fill pump and filter. 3. If there is any doubt regarding the absolute cleanliness of the system, fit high pressure bi-direction filters in high pressure lines as shown in following diagram. the filters are in addition to the installed suction and return filters.

M

4. Check that all filters have elements of the correct rating and the filter housing are filled with the hydraulic fluid to be used in the system. 5. Where possible, fill the high pressure lines. 6. Open suction line valves.

A flushing valve is available for manifold mounting on the rear cover of an AA6VM motor. This valve provides a regulated flow of oil from the low pressure side of the loop into the motor case. This oil is used to cool and flush the motor bearings. Note: Consult Rexroth application engineer to determine if a motor flushing valve is required for your application.

7. Fill pump and motor case to the highest drain or vent port. 8. Check that all pressure connections are secure. 9. Ensure all mechanical gear boxes have the correct oil type and are filled to the prescribed level.

B

10. Fully back off all high pressure relief valves and then reset one half turn against the spring. 11. Fit 10,000 psi pressure gauges to each high pressure line. 12. Fit 500 psi pressure gauges to charge and pilot circuits. 13. Fit 100 psi pressure gauge to pump case drain port. 14. Fit vacuum gauge to the charge pump suction line, as close as possible to suction port.

TG

A

EP1 and EP2 Control with Flushing Valve

Filtration The fluid should be filtered prior to system start-up, and continuously during operation to achieve and maintain a cleanliness level of ISO 18/15 (This corresponds approximately to NAS 1638 class 9, or SAE [1963] Class 6.) This recommendation should be considered a minimum, as better cleanliness levels will significantly increase component life.

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15. Release brakes and jack up the driving wheels. Winches should be started without the cable fitted. 16. Ensure that the fluid temp. in the reservoir is 45F or higher. 17. Ensure that the motor minimum displacement (maximum speed) is set correctly as shown on page 23.

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Travel Drive Motor Installation, Start-up, & Troubleshooting All Grayhound Series Pavers Start-Up Procedure The following procedure has been developed based on experience with most types of applications, however certain applications may require a departure from or variation to this procedure. For the start-up of new or overhauled installations. 18. Check oil level and temperature.

1. If the prime mover is: Internal combustion engine: (Diesel, gasoline or LP)Remove the coil wire, close the injector rack or leave the gas turned off and turn the engine over until the charge pressure reaches 50 psi or more. Electric Motor: Jog the starting circuit until the charge pressure reaches 50 psi or more. 2. Start the prime mover, and if possible, maintain a pump speed of approximately 750 rpm for 5 minutes. This will allow the system to be filled.

19. Remove and inspect high pressure filter elements, if so equipped. Replace with new elements. 20. Operate transmission under no load conditions for about 15 minutes to stabilize the temperature and remove any residual air from the fluid. 21. Again remove and inspect high pressure filter elements, “if so equipped.” If clean, the high pressure, bi-direction filters may be removed from the circuit. If contamination is still evident, fit new elements and continue flushing until the system is clean.

3. Listen for any abnormal noises. 4. Check for oil leaks.

22. Replace the elements in the charge pump suction or pressure filter, whichever is installed.

5. Run prime mover to 1800 rpm. (Adjust to the design speed if less than 1800 rpm.)

23. Operate the transmission under full and normal load conditions.

6. Set charge and pilot pressure as required for the application. (Refer to circuit schematic)

24. Erratic operation may indicate there is still air trapped in the system. By working the pump control to one or both sides the remaining air can be eliminated. The system is free of air when all functions can be operated smoothly and when the oil in the reservoir is no longer aerated. (Usually less than 1 hour of operation)

7. Bleed the pilot lines by loosening the connections on the motor “X” port(s) and then actuate the remote control unit in both directions until oil seeps from the connections. Also bleed the pilot lines to the pump (if any). 8. Retighten all connections. 9. Operate the control to work the hydrostatic transmission at approximately 20% of maximum speed.

Note: If, after following the Pre-Start and Start-up procedures, the transmission does not perform correctly, refer to the relevant sections of the trouble-shooting procedures on pages 17, 18 & 19.

10. Deaerate system by venting a bleed valve or by cracking the highest connection until fluid seeps out without bubbles. 11. Check fluid level and add fluid if necessary. 12. Continue operating transmission and gradually increase to full speed, still with no load. 13. With controls neutralized, check for creep in neutral. If evident, center the control in accordance with the instructions in the pump service manual. 14. Check that the controls are connected so that the transmission operates in the correct direction related to the control input. 15. Continue to monitor all pressure gauges and correct any irregularities. 16. Apply brakes and set high pressure relief valves (and pressure override if installed) to levels required for the application by stroking the pump to approximately 20% of maximum displacement. 17. Check security of high pressure connections.

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Travel Drive Motor Installation, Start-up, & Troubleshooting All Grayhound Series Pavers Troubleshooting Procedure To aid in troubleshooting, refer also to the Hydrostatic Transmission Pump Service Manual. Procedure assumes gauges are installed.

This procedure was written to aid the troubleshooter in following a logical approach to a system fault.

1. Transmission does not Drive with the Prime Mover Running 1.1 Is there oil in the reservoir?

No Fill reservoir. Yes Proceed to step1.2.

1.2 Is engine clutch engaged?

No Engage clutch. Yes Proceed to step 1.3.

1.3 Is the hydraulic piping in accordance with the hydraulic circuit?

No Correct the piping. Yes Proceed to step 1.4.

1.4 Is the pump direction of rotation correct?

No Fit pump having the correct direction of rotation. Yes Proceed to step 1.5.

1.5 Is there a broken pipe, loose fitting or burst hose?

No Proceed to step 1.6. Yes Repair the fault.

1.6 Are the brakes released?

No Check brake release circuit or mechanism. Yes Proceed to step 1.7.

1.7 Is there any charge pressure?

No Proceed to step 1.10. Yes Proceed to step 1.8.

1.8 Is the charge circuit at the recommended pressure level while the pump is running at normal operating speed?

No Proceed to step 1.9. Yes Proceed to step 1.19.

1.9 Can the charge pressure be adjusted at the charge pressure relief valve?

No Proceed to step 1.10. Yes Adjust charge pressure and proceed to step 1.19.

1.10 Is the suction line shutoff?

No Open valve Yes Proceed to step 1.11.

1.11 Is the charge pump suction pressure within the recommended limits?

No Proceed to step 1.12. Yes Proceed to step 1.16.

1.12 Is the suction filter element plugged.

No Proceed to step 1.13. Yes Replace filter element

1.13 Does the reservoir design ensure that suction pipe is always covered with oil.

No Correct the reservoir design. Yes Proceed to step 1.14.

1.14 Is the suction pipe size adequate for the flow?

No Run at lower speed and return to point 1.7, or rework suction piping. Yes Proceed to step 1.15.

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1.15 Is the reservoir air breather blocked or undersized?

No Proceed to step 1.16. Yes Clean or Replace air breather.

1.16 Remove charge pressure relief valve cartridge and inspect. Is it damaged?

No Refit cartridge and proceed to step 1.17. Yes Fit a new cartridge and return to step 1.7.

1.17 Remove and inspect charge pump assembly. Is it damaged?

No Proceed to step 1.18. Yes Repair or replace damaged components and return to step 1.7.

1.18 Is the charge pump installed for correct direction of rotation?

No Refit charge pump. Return to step 1.7. Yes With proper charge pressure, and transmission still does not operate, proceed to step 1.19.

1.19 Is control medium connected to pump control? Hydraulic pilot pressure mechanical cable or linkage. 12 or 24 volts dc, electrical current.

No Connect appropriate medium and check that control signal is actually being applied to the pump stroker. Yes Proceed to step 1.20.

1.20 Is maximum displacement selected on the variable motors? (If not done automatically)

No Select maximum displacement. Yes Proceed to step 1.21.

1.21 Actuate the control in both directions. Does pump stroke? Does it go to full stroke?

No Refer to the pump service manual and then proceed to step 1.22. Yes Operate the transmission.

1.22 Is it possible to adust high pressure relief valves?

No Replace high pressure relief valve cartridges and return to step 1.21. Yes Adjust high pressure relief valves

1.23 Actuate control in both directions. Does transmission run?

No Check if motor sizing is adequate for application. Check for excessive motor leakage and replace motor if defective. Check for mechanical faults in the drive beyond the motor shaft. Yes Operate the transmission.

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Travel Drive Motor Installation, Start-up, & Troubleshooting All Grayhound Series Pavers Troubleshooting Procedure 2. Transmission Drive is Sluggish or Erratic 2.1 Is the control medium in good condition? For example: control medium is not in good condition if: The hydraulic pilot pressure lines have air in them, the manual control cable or linkage is sticking, or the electrical control current is fluctuating. (pump and/or motor)

No Rectify the control fault. Bleed pilot lines. Lubricate or free the cable or linkage. Check control current. Yes Proceed to step 2.2.

2.2 Are the brakes fully released?

No Check brake release circuit or mechanism. Yes Proceed to step 2.3.

2.3 Is the pump stroking time correct for the application?

No Correct pump stroking time. Yes Proceed to step 2.4.

2.4 With hydraulic pilot control, is the contol curve of remote pilot valve correctly matched to the motor?

No Change spring to suit. Yes Proceed to step 2.5.

2.5 Does the charge pressure fluctuate more than 30 psi when stroking the pump?

No Proceed to 2.9 Yes Proceed to step 2.6.

2.6 If the charge pump output is used to operate auxilary functions, do these other functions cause fluctuations in charge pressure?

No Proceed to 2.8 Yes Proceed to step 2.7.

2.7 Isolate the auxilary function and run the transmission. Are the charge pressure fluctuations reduced or eliminated?

No Proceed to 2.8 Yes Operate transmission and return to step 2.1.

2.8 Are there system pressure fluctuations which are syncronous with the charge pressure flucuations?

No Proceed to step 2.9. Yes Determine the cause of system pressure fluctuations.

2.9 Is the motor stroking time correct for the application?

No. Add motor stroking time adjustment valve or orifice to the variable motor, or modify the control circuit to provide desired stroking time.

3. Transmission Drives in One Direction Only 3.1 Is it possible that the control signal to one side of the pump does not work properly?

No Proceed to step 3.2. Yes Refer to pump sevice manual.

3.3 Switch releif valves. Does the transmission drive in the other direction only?

No Proceed to step 3.4. Yes Repair or replace releif valve on non-driving side.

3.2 Check flushing valve (if installed). Is shuttle spool stuck in one position?

No (Not installed). Yes Remove flushing valve and clean or replace.

3.4 Actuate control. Does the transmission run in both directions?

No Check for mechanical faults in the drive beyond the motor shaft. Yes Operate the transmission.

4.2 To change direction at motor:

Switch the high pressure lines at ports A and B.

4. Transmission Drives in the Wrong Direction 4.1 To change direction at pump:

Pumps - Motors - Drives

Switch the control signal lines or linkage to the pump control module or stroker.

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Travel Drive Motor Installation, Start-up, & Troubleshooting All Grayhound Series Pavers Troubleshooting Procedure 5. Insufficient Output Torque in One or Both Directions 5.1 Using the 0–10,000 psi gauges, is the load side of the loop required or design pressure?

No Review steps 1.1 through 1.22. Yes Proceed to step 5.2.

5.2 Is the motor receiving the hydraulic or electrical control signal on the control spool? (HD & EL)

No Correct problem. Yes Proceed to step 5.3.

5.3 Is the motor begin of stroke set correctly? For example, the output torque may be low if the begin of stroke is: HD & EL controls-set too low. HA-control-set too high.

No Set begin of stroke per page 21. Yes Proceed to step 5.4.

5.4 With a pressure gauge at port G, does G port pressure match system high pressure with either port A or B pressurized?

No Replace faulty motor. Yes Proceed to step 5.5.

5.5 Is output torque sufficient in both directions?

No Check if motor sizing is adequate for application. Check for mechanical faults or improper design sizing in the drive beyond the motor shaft. Yes Operate the transmission.

6.4 Is the suction pressure at the charge pump inlet within recomended limits?

No Return to step 1.7. Yes Proceed to step. 6.5.

6.5 Is there air in the hydraulic oil? This may be indicated by foaming or milky colored oil.

No Proceed to step 6.6. Yes Deaerate the oil and inspect system for cause of air induction.

6.6 Is the hydraulic motor operating at excessive speed?

Yes Check motor sizing in relation to available oil flow from the pump. check motor minimum displacement. See page 20.

6. Transmission Drives at a High Noise Level 6.1 Are the drive gearboxes filled with correct grade of oil?

No Fill gearbox with correct grade of oil to the prescribed level. Yes Proceed to step 6.2.

6.2 Is the drive coupling correctly installed and aligned?

No Install coupling per manufacturer’s instructions and tolerances. Yes Proceed to step 6.3.

6.3 Is rigid piping connected to the pump and motor?

No Proceed to step 6.4 Yes Install short length of hose between pressure ports and the system piping.

7. Transmission Operates at a Higher Than Normal Temperature 7.1 Is the operating temperature above 195F? 7.2 Does temperature remain above 195F after cleaning oil cooler? 7.3 Is the hydaulic motor stalling intermittently?

Pumps - Motors - Drives

No 195F is the upper limit. If temp. is close to 195F the oil cooler may need to be cleaned. Yes Proceed to step 7.3.

7.4 Check differential pressure across oil cooler as compared to the manufacturer’s specs at charge pump flow. Is ∆P higher than it should be?

No Proceed to 7.4. Yes Hydraulic oil is being heated through system releif valves. Shut down system and rectify cause of the motor stall.

Note: See page 7 for case pressure rating.

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7.5 Disconnect pump case drain from oil cooler and check flow from charge pump. Is flow normal?

No Proceed to step 7.5 Yes Check piping from oil cooler to tank or plugged oil cooler.

No Refer to charge pump removed and inspection procedure. Yes Check oil cooler location.

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Travel Drive Units/Motors All Grayhound Series Pavers

The Following Pages and information are take from Portions of Manuals, Form Numbers: 19353 GFT 25T2.1017 19376 GFT 36E.1051 19378 GFT 36E.1040 20267 GFT 56T2.1074 20410 GFT 25T2.1092 20966 GFT 44T2.1123 21020 GFT 44T2.1124 21062 GFT 36E.1060 21147 GFT 25T2.1152 21747 GFT 26T2.1026 21865 GFT 40T2.9202 21866 GFT 40T2.9228 22190 GFT 40T2.9296 22528 GFT 50T3.9311 Lohmann & Stolterfoht Drive w/Rexroth Motor

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XX

(See Attached Table)

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(See Attached Table)

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Travel Drive Unit Data All Grayhound Series Pavers CR Part No. 45080-004-75 Lohmann & Stolterfoht GFT 36E.1040

CR Part No. 45080-004-88 Lohmann & Stolterfoht GFT 36E.1051

Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Gear Lubrication Group

Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Gear Lubrication Group

See Rating Plate See Rating Plate See Rating Plate 27,730 ft. lbs. 4500 rpm 58.3 PP 100

See Rating Plate See Rating Plate See Rating Plate 27,730 ft. lbs. 4500 rpm 58.3 CLP 150

It is important to quote the full drive designation, serial and order numbers when ordering spare parts.

It is important to quote the full drive designation, serial and order numbers when ordering spare parts.

Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

2/6061/5040/1 1/6061/1040/0 4/6061/3040/0

Hydraulic Motor CR Part No. 45080-004-75-08 Rexroth A6VE107HA2T/63W0352-PVU027A

2/6061/5051/1 4/6061/1551/0 4/6061/3051/0

Hydraulic Motor CR Part No. 45080-004-75-08 Rexroth A6VE107HA2T/61W0352-PVU027A

CR Part No. 45080-004-89 Lohmann & Stolterfoht GFT 56T2.1074 CR Part No. 45080-004-85 Lohmann & Stolterfoht GFT 25T2.1017 Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Gear Lubrication Group

Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Gear Lubrication Group

See Rating Plate See Rating Plate See Rating Plate 16,336 ft. lbs. 5000 rpm 50.4 CLP 150

Approx. Capacity

See Rating Plate See Rating Plate See Rating Plate 31,093 ft. lbs. 4526 rpm 62 CLP 220 L&S LubeGroup LS-2 1.75 Gallons

It is important to quote the full drive designation, serial and order numbers when ordering spare parts.

It is important to quote the full drive designation, serial and order numbers when ordering spare parts.

Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

2/6111/5017/3 4/6111/1517/0 4/6111/3017/0

Hydraulic Motor CR Part No. 45080-004-85-01 Rexroth A6VE80HA2T/61W0263-PAU027A

Pumps - Motors - Drives

2/6091/5074/0 1/6091/1074/0 4/6091/2074/0

Hydraulic Motor CR Part No. 45080-004-75-08 Rexroth A6VE107HA2T/61W0352-PVU027A

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Travel Drive Unit Data All Grayhound Series Pavers CR Part No. 45080-004-98 Lohmann & Stolterfoht GFT 25T2.1092

CR Part No. 45080-006-04 Lohmann & Stolterfoht GFT 44T2.1123

Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Brake Holding Torque (input) Gear Lubrication Group

Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Gear Lubrication Group

Approx. Capacity

See Rating Plate See Rating Plate See Rating Plate 16,336 ft. lbs. 5000 rpm 50.4 413 ft. lbs. CLP 220 L&S LubeGroup LS-2 1 Gallon

Approx. Capacity

It is important to quote the full drive designation, serial and order numbers when ordering spare parts.

It is important to quote the full drive designation, serial and order numbers when ordering spare parts. Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

See Rating Plate See Rating Plate See Rating Plate 29,257 ft. lbs. 4500 rpm 58.3 CLP 220 L&S LubeGroup LS-2 1.75 Gallons

Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

2/6111/5092/0 1/6111/1092/0 7/6111/2092/0

2/6108/5123/1 0/6108/1123/0 7/6108/2123/0

Hydraulic Motor CR Part No. 45080-004-75-08 Rexroth A6VE107HA2T/61W0352-PVU027A

Hydraulic Motor CR Part No. 45080-004-98-01 Rexroth A6VE80HA2T/61W0263-PAL027A

CR Part No. 45080-006-03 Lohmann & Stolterfoht GFT 36E.1060

CR Part No. 45080-006-05 Lohmann & Stolterfoht GFT 44T2.1124

Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Gear Lubrication Group

Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Gear Lubrication Group

Approx. Capacity

See Rating Plate See Rating Plate See Rating Plate 27,730 ft. lbs. 4500 rpm 58.3 CLP 220 L&S LubeGroup LS-2 1.1 Gallons

Approx. Capacity

See Rating Plate See Rating Plate See Rating Plate 29,257 ft. lbs. 4500 rpm 58.3 CLP 220 L&S LubeGroup LS-2 1.75 Gallons

It is important to quote the full drive designation, serial and order numbers when ordering spare parts.

It is important to quote the full drive designation, serial and order numbers when ordering spare parts.

Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

2/6061/5060/0 0/6061/1060/0 7/6061/2060/0

Hydraulic Motor CR Part No. 45080-006-03-01 Rexroth A6VE107HA2T/61W0352-VZL027A

Pumps - Motors - Drives

2/6108/5124/0 0/6108/1124/0 7/6108/2124/0

Hydraulic Motor CR Part No. 45080-006-03-01 Rexroth A6VE107HA2T/61W0352-VZL027A

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Travel Drive Unit Data All Grayhound Series Pavers CR Part No. 45080-006-08 Lohmann & Stolterfoht GFT 25T2.1152

CR Part No. 45080-006-22 Lohmann & Stolterfoht GFT 26T2.1026

Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Brake Holding Torque (input) Gear Lubrication Group

Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Brake Holding Torque (input) Gear Lubrication Group

Approx. Capacity

See Rating Plate See Rating Plate See Rating Plate 16,336 ft. lbs. 5000 rpm 50.4 413 ft. lbs. CLP 220 L&S LubeGroup LS-2 1 Gallon

Approx. Capacity

See Rating Plate See Rating Plate See Rating Plate 18,710 ft. lbs. 4767 rpm 50.5 527 ft. lbs. CLP 220 L&S LubeGroup LS-2 1 Gallon

It is important to quote the full drive designation, serial and order numbers when ordering spare parts.

It is important to quote the full drive designation, serial and order numbers when ordering spare parts.

Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

2/6111/5152/0 1/6111/1152/0 7/6111/2152/0

1/6171/5026/0 0/6171/1026/0 7/6171/2026/0

Hydraulic Motor CR Part No. 45080-006-08-01 Rexroth A6VE80HA2T/63W0263-VAL027A

Hydraulic Motor CR Part No. 45080-006-08-01 Rexroth A6VE80HA2T/63W0263-VAL027A

CR Part No. 45080-006-20 Lohmann & Stolterfoht GFT 40T2.9202

CR Part No. 45080-006-23 Lohmann & Stolterfoht GFT 40T2.9228

Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Brake Holding Torque (input) Gear Lubrication Group

Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Brake Holding Torque (input) Gear Lubrication Group

Approx. Capacity

See Rating Plate See Rating Plate See Rating Plate 29,661 ft. lbs. 4500 rpm 59.1 590 ft. lbs. CLP 220 L&S LubeGroup LS-2 1.1 Gallons

Approx. Capacity

It is important to quote the full drive designation, serial and order numbers when ordering spare parts. Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

It is important to quote the full drive designation, serial and order numbers when ordering spare parts. Installation Drawing with Technical Data 1/6167/5228/0 Spare Parts Drawing 0/6167/1228/0 Spare Parts List 7/6167/2228/0

1/6167/5202/0 0/6167/1202/1 7/6167/2202/2

Hydraulic Motor CR Part No. 45080-006-23-01 (Motor Displacement Modified Per Above Print) Rexroth A6VE160HA2T/63W-VZL027A

Hydraulic Motor CR Part No. 45080-006-03-01 Rexroth A6VE107HA2T/63W0352-VZL027A

Pumps - Motors - Drives

See Rating Plate See Rating Plate See Rating Plate 29,485 ft. lbs. 4055 rpm 35.9 590 ft. lbs. CLP 220 L&S LubeGroup LS-2 1.1 Gallons

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Travel Drive Unit Data All Grayhound Series Pavers CR Part No. 45080-006-29 Lohmann & Stolterfoht GFT 40T2.9296 Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Brake Holding Torque (input) Gear Lubrication Group Approx. Capacity

See Rating Plate See Rating Plate See Rating Plate 29,485 ft. lbs. 4055 rpm 35.9 590 ft. lbs. CLP 220 L&S LubeGroup LS-2 1.1 Gallons

It is important to quote the full drive designation, serial and order numbers when ordering spare parts. Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

1/6167/5296/0 0/6167/1296/0 16218282

Hydraulic Motor CR Part No. 45080-006-29-01 Rexroth A6VE160HA2T/63W-VZL027A CR Part No. 45080-006-31 Lohmann & Stolterfoht GFT 50T3.9311 Serial No. Order No. Year of Mfg. Output Torque Input Speed Gear Ratio Brake Holding Torque (input) Gear Lubrication Group Approx. Capacity

See Rating Plate See Rating Plate See Rating Plate 36,878 ft. lbs. 3820 rpm 66.3 590 ft. lbs. CLP 220 L&S LubeGroup LS-2 1.1 Gallon

It is important to quote the full drive designation, serial and order numbers when ordering spare parts. Installation Drawing with Technical Data Spare Parts Drawing Spare Parts List

1/6167/5311/0 0/6167/1311/0 16558180

Hydraulic Motor CR Part No. 45080-006-31-02 Rexroth A6VE107HA2T/63W0317-VZL027A

Pumps - Motors - Drives

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Pumps - Motors - Drives

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PAVER TECHNICAL MANUAL

Automatic Feed & Grade Control Section

Technical Manual

A Terex Company

Table of Contents Automatic Feed & Grade Control Section

Description ................................................................................... Page /Form AUTOMATIC FEED & GRADE CONTROL TROUBLESHOOTING Component Location Map 1st Generation Version Grayhound 300 Series Analog Display ............................................................................... 1 Component Location Map 2nd Generation Version Grayhound 300 Series Analog Display ............................................................................... 2 Component Location Map Grayhound 400 Series Digital Display ................................................................................ 3 Component Location Map 1st Generation Version Grayhound 400/500 Series Analog Display ........................................................................ 4 Component Location Map 2nd Generation Version Grayhound 400/500 Series Analog Display ........................................................................ 5 Component Location Map 3rd Generation Version Grayhound 400/500 Series Analog Display ........................................................................ 6 Component Location Map Grayhound 400/500 Series Remix Pavers ........................................................................... 7 Component Location Map All Grayhound Series Pavers ............................................................................................... 9 LH Conveyor Manual Mode Grayhound Analog Display ............................................................................................... 10 RH Conveyor Manual Mode Grayhound Analog Display ............................................................................................... 11 LH Conveyor Auto Mode Grayhound Analog Display ............................................................................................... 12 RH Conveyor Auto Mode Grayhound Analog Display ............................................................................................... 13 LH Conveyor Adjustment Procedure Grayhound Analog Display ............................................................................................... 14 RH Conveyor Adjustment Procedure Grayhound Analog Display ............................................................................................... 15

Automatic Feed & Grade Control

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Table of Contents - Cont. Automatic Feed & Grade Control Section LH Automatic Screed Control Grayhound Analog Display ........................................................................................ 16 - 17 RH Automatic Screed Control Grayhound Analog Display ........................................................................................ 18 - 19 Generation III Sonics 1st Generation Controls Grayhound Pavers .............................................................................................................. 20 Generation III Sonics 2nd Generation Controls Grayhound Pavers .............................................................................................................. 21 Generation III Sonics Conveyor Control 3rd Generation Controls Grayhound Pavers 1999 & After ................................................................................ 22 - 23 Amplifier Module Grade Systems ................................................................................................................... 24 Amplifier Module Slope Systems .................................................................................................................... 25 Remote Slope Set .............................................................................................................. 26 Slope Sensor Checks ......................................................................................................... 27 System 4 LH Automatic Screed Control Grayhound Pavers 1999 & Before .............................................................................. 28 - 29 System 4 LH Automatic Screed Control Grayhound Pavers 1999 & After ................................................................................ 30 - 31 System 4 RH Automatic Screed Control Grayhound Pavers 1999 & Before .............................................................................. 32 - 33 System 4 RH Automatic Screed Control Grayhound Pavers 1999 & After ................................................................................ 34 - 35 Remix Delivery Control All Grayhound Pavers ................................................................................................. 36 - 38 Remix Delivery Control Re-Work Kit Wiring Diagram & Installation Instructions ............................................................... 39 - 43 AUTOMATIC FEED & GRADE CONTROL MANUALS Generation III Sonic Feed Control .................................................................... Form 20576 Sundstrand Automatic Grade & Slope Control ................................................. Form 18121 Topcon System Four Grade & Slope Control .................................................... Form 21048 SMOOTHTRAC™ Sonic Averaging System (SAS) ......................................... Form 22506 Automatic Feed & Grade Control

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Component Location Map 1st Generation Version Grayhound 300 Series Analog Display 24 23 22 21 20 19 18 17 16 15 1 2 3 4 5 6 7 8 9

12 14

13 10

11

1 ........... Engine breaker: 15 amp 2 ........... Screed breaker: 15 amp 3 ........... Control breaker: 15 amp 4 ........... F/G/S breaker: 15 amp 5 ........... Spraydown breaker: 15 amp 6 ........... Light breaker: 15 amp 7 ........... Flasher breaker: 15 amp 8 ........... Gate breaker: 30 amp 9 ........... Burner breaker: 50 amp 10 ......... Key switch 11 ......... K2 relay 12 ......... K22 relay

Automatic Feed & Grade Control

13 ......... RH auger/conveyor proportional module 14 ......... LH auger/conveyor proportional module 15 ......... K3 relay 16 ......... K4 relay 17 ......... K5 relay 18 ......... K6 relay 19 ......... K15 relay 20 ......... K16 relay 21 ......... K17 relay 22 ......... K18 relay 23 ......... Spare relay 24 ......... Flasher relay

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A Terex Company

Component Location Map 2nd Generation Version Grayhound 300 Series Analog Display 23 22 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9

13

10

11

12

1 ........... Engine breaker: 15 amp 2 ........... Screed breaker: 15 amp 3 ........... Control breaker: 15 amp 4 ........... F/G/S breaker: 15 amp 5 ........... Spraydown breaker: 15 amp 6 ........... Light breaker: 15 amp 7 ........... Flasher breaker: 15 amp 8 ........... Gate breaker: 30 amp 9 ........... Burner breaker: 50 amp 10 ......... Key switch 11 ......... K2 relay 12 ......... Cooler breaker: 50 amp

Automatic Feed & Grade Control

13 ......... Feed Interface Module 14 ......... Cooler relay 15 ......... K3 relay 16 ......... K4 relay 17 ......... K5 relay 18 ......... K6 relay (flasher) 19 ......... K15 relay 20 ......... K16 relay 21 ......... K17 relay 22 ......... K18 relay 23 ......... K22 relay

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Component Location Map Grayhound 400 Series Digital Display

L44

L42 L43 L40

L46 L45

L41

L47

L48

L49

L50

L54 L51 L53

L40 ....... Master key L41 ....... Detroit governor card/feeder resistor card L42 ....... 60 amp breaker (burner) L43 ....... 15 amp breaker (power) L44 ....... 15 amp breaker (control) L45 ....... 15 amp breaker (flasher) L46 ....... 15 amp breaker (Lights) L47 ....... RH flow gate relay (lower)

Automatic Feed & Grade Control

3

L48 ....... LH flow gate relay (raise) L49 ....... RH flow gate relay (lower) L50 ....... LH flow gate relay (raise) L51 ....... Proportional module L52 ....... Horn relay L53 ....... Terminal block L54 ....... Murphy timer relay

22482 (10/01)

Technical Manual

A Terex Company

Component Location Map 1st Generation Version Grayhound 400/500 Series Analog Display

13 12 11 10

9 8

7

6

5

4

3

2

1

14

15 16

1 ........... Timing relay 2 ........... Engine breaker 15 amp 3 ........... Light breaker 15 amp 4 ........... Flasher breaker 15 amp 5 ........... Control breaker 15 amp 6 ........... Power breaker 30 amp 7 ........... Burner breaker 60 amp 8 ........... Spare relay 9 ........... K3 relay 10 ......... K15 relay 11 ......... K16 relay 12 ......... K17 relay 13 ......... K18 relay 14 ......... RH auger/conveyor proportional module 15 ......... LH auger/conveyor proportional module 16 ......... K1 relay

Automatic Feed & Grade Control

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Component Location Map 2nd Generation Version Grayhound 400/500 Series Analog Display

24 23 22 21 20 19 18 17 16 15 1 2 3 4 5 6 7 8 9

12 14

13 10

11

1 ........... Engine breaker: 15 amp 2 ........... Screed breaker: 15 amp 3 ........... Control breaker: 15 amp 4 ........... F/G/S breaker: 15 amp 5 ........... Spraydown breaker: 15 amp 6 ........... Light breaker: 15 amp 7 ........... Flasher breaker: 15 amp 8 ........... Gate breaker: 30 amp 9 ........... Burner breaker: 50 amp 10 ......... Key switch 11 ......... K2 relay 12 ......... K22 relay

Automatic Feed & Grade Control

13 ......... RH auger/conveyor proportional module 14 ......... LH auger/conveyor proportional module 15 ......... K3 relay 16 ......... K4 relay 17 ......... K5 relay 18 ......... K6 relay 19 ......... K15 relay 20 ......... K16 relay 21 ......... K17 relay 22 ......... K18 relay 23 ......... Spare relay 24 ......... Flasher relay

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A Terex Company

Component Location Map 3rd Generation Version Grayhound 400/500 Series Analog Display

22 21 20 1918 17 16 15 14 13 1 2 3 4 5 6 7 8 9

12

10

11

12 ......... Feed Interface Module 13 ......... K3 relay 14 ......... K4 relay 15 ......... K5 relay 16 ......... K6 relay 17 ......... K15 relay 18 ......... K16 relay 19 ......... K17 relay 20 ......... K18 relay 21 ......... K22 relay 22 ......... Spare relay

1 ........... Engine breaker: 15 amp 2 ........... Screed breaker: 15 amp 3 ........... Control breaker: 15 amp 4 ........... F/G/S breaker: 15 amp 5 ........... Spraydown breaker: 15 amp 6 ........... Light breaker: 15 amp 7 ........... Flasher breaker: 15 amp 8 ........... Gate breaker: 30 amp 9 ........... Burner breaker: 50 amp 10 ......... Key switch 11 ......... K2 relay

Automatic Feed & Grade Control

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Component Location Map Grayhound 400/500 Series Remix Pavers

21 19 18 17 16

K4

E

20

K3

K5

AR

K6

SP

15

13

14

FEED INTERFACE MODULE

1 2 3 4 5 6 7 8 9 10

11

12

1 ........... Engine breaker: 15 amp 2 ........... Screed breaker: 15 amp 3 ........... Console breaker: 15 amp 4 ........... F/G/S breaker: 15 amp 5 ........... Spraydown breaker: 15 amp 6 ........... Light breaker: 15 amp 7 ........... Flasher breaker: 15 amp 8 ........... Gate breaker: 30 amp 9 ........... Burner breaker: 50 amp 10 ......... Key switch 11 ......... K2 relay

Automatic Feed & Grade Control

12 ......... RH & LH Feed Interface Module 13 ......... Spare Feed Interface Module 14 ......... RH Remix Controller 15 ......... LH Remix Controller 16 ......... K3 relay 17 ......... K4 relay 18 ......... K5 relay 19 ......... K6 relay 20 ......... K22 relay 21 ......... Spare relay

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Automatic Feed & Grade Control

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Component Location Map All Grayhound Series Pavers L4

L2 L1

L3

L5

L6

Front Bulkhead L17 L9

L12

L8 L7

L16 L11

L13

L10

Rear Bulkhead

L14 L15

L1 ......... Slope sensor L2 ......... Front wheel assist L3 ......... LH pull point solenoid L4 ......... Truck hitch solenoid L5 ......... LH material flow gate L6 ......... RH material flow gate L7 ......... Main electrical junction box L8 ......... Hopper wing solenoid L9 ......... RH pull point solenoid L10 ....... Screed lift solenoid L11 ....... Frame raise solenoid L12 ....... Brake solenoid L13 ....... Vibrator solenoid L14 ....... LH feed sensor L15 ....... RH feed sensor L16 ....... Travel/Pave solenoid L17 ....... Burner/Spraydown pump & motor

Automatic Feed & Grade Control

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LH Conveyor Manual Mode Grayhound Analog Display Main Keyswitch

12 VDC 0

1

LH Conveyor

Control 1

46

3

Auto Off

15 A

LH Feed Control

Man 46 55 Remote Feed Override 46

(3) 55

(9)

84

(2)

(8) 85

52 (1)

86 Adjust (10) Speed 3 Module (11)

(5)

'C' Stop 46

(7)

(6) 46

(12)

B CW C A

3 'C' 87

(4)

83

Man Conv Speed 1K

LH Feed Servo B

3

A

Stop

LH CONVEYOR DOES NOT RUN IN MANUAL MODE Main key switch ON, engine RUNNING, control circuit breaker SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. LH conveyor switch to MANUAL. 55 to 3 ........ If no voltage (12 Vdc), defective LH conveyor switch. 85 to 3 ........ Voltage should vary from approximately 6.5 to 9 Vdc as conveyor speed dial is rotated. If voltage does not vary, check conveyor speed pot for resistance: Pin B to A .. 1000 ±100 ohms at all times. Pin B to C .. Ohms should vary as speed pot is rotated. Pin A to C .. Ohms should vary as speed pot is rotated. 83 to 3 ........ If no voltage, defective conveyor speed module. (Voltage should not read 12 Vdc.) Voltage should vary from 0.2 to 2.2 Vdc as conveyor speed dial is rotated. If 12 Vdc is present 87 to 3..........If no voltage, defective override/stop switch or open wiring to screed. Voltage should vary from 0.2 to 2.2 Vdc as conveyor speed dial is rotated. If 12 Vdc is present, LH feed servo is open or open wiring to servo: Main key switch OFF. Pins A to B should read 19.5 ohms resistance. If not, defective servo. If 19.5 ohms, open wiring. CONVEYOR CANNOT BE STOPPED BY OVERRIDE/STOP SWITCH LH conveyor switch to MANUAL, LH override/stop switch to STOP. LH conveyor should stop. If not, defective LH override/stop switch. CONVEYOR CANNOT BE STARTED BY OVERRIDE/STOP SWITCH LH conveyor switch to STOP, LH conveyor speed dial to MAX., LH override switch to OVERRIDE. 52 to 3 ........ If no voltage, defective override/stop switch. If 12 Vdc, replace module. Automatic Feed & Grade Control

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RH Conveyor Manual Mode Grayhound Analog Display Main Keyswitch

12 VDC 0

1

RH Conveyor

Control 1

46

3

Auto Off

15 A

RH Feed Control

Man 46 56 Remote Feed Override 46

(3) 56

(9)

94

(2)

(8) 95

54 (1)

96 Adjust (10) Speed 3 Module (11)

(5)

'D' Stop 46

(7)

(6) 46

(12)

B CW C A

3 'D' 97

(4)

93

Man Conv Speed 1K

RH Feed Servo B

3

A

Stop

RH CONVEYOR DOES NOT RUN IN MANUAL MODE Main key switch ON, engine RUNNING, control circuit breaker SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. RH conveyor switch to MANUAL. 56 to 3 ........ If no voltage (12 Vdc), defective LH conveyor switch. 95 to 3 ........ Voltage should vary from 6.5 to 9 Vdc as conveyor speed dial is rotated. If voltage does not vary, check conveyor speed pot for resistance: Pin B to A .. 1000 ±100 ohms at all times. Pin B to C .. Ohms should vary as speed pot is rotated. Pin A to C .. Ohms should vary as speed pot is rotated. 93 to 3 ........ If no voltage, defective conveyor speed module. Voltage should vary from 0.2 to 2.2 Vdc as conveyor speed dial is rotated. If 12 Vdc is present: 97 to 3 ........ If no voltage, defective override/stop switch or open wiring to screed. Voltage should vary from 0.2 to 2.2 Vdc as conveyor speed dial is rotated. If voltage (12 Vdc), RH feed servo is open or open wiring to servo: Main key switch OFF, pins A to B on servo should read 19.5 ohms resistance. If not, defective servo. If 19.5 ohms, open wiring. CONVEYOR CANNOT BE STOPPED BY OVERRIDE/STOP SWITCH RH conveyor switch to MANUAL. RH override/stop switch to STOP. RH conveyor should stop. If not, defective RH override/stop switch. CONVEYOR CANNOT BE STARTED BY OVERRIDE/START SWITCH RH conveyor switch to STOP, RH conveyor speed dial to MAX, RH override switch to OVERRIDE. 54 to 3 ........ If no voltage, defective override/stop switch. If 12 Vdc, replace module Automatic Feed & Grade Control

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LH Conveyor Auto Mode Grayhound Analog Display Main Keyswitch

1

1

12 VDC 3

0 Control 46

46

Brake

Note: Closed in forward (travel control) 34 47

Engage

'A' Release

15 A

LH Conveyor Auto 47 Off Man 55

46

Remote Feed Override 'C' Stop

46

Forward L.S.

47

LH Feed Control Feed Sensor (C) (E) (D)

51

3

3

80 51

(7)

84

Man. B CW Conv. 85 (2) (8) C Adjust. Speed 52 (1) Speed (10) 86 A 1K 3 3 (5) Module (11) LH Feed Servo (6) 'C' 87 3 46 83 B A (4) (12) (3)

(9)

55

Stop

LH CONVEYOR DOES NOT RUN IN AUTO MODE Main key switch ON, engine RUNNING, control circuit breaker SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. LH conveyor switch to AUTO, brakes RELEASED, travel lever(s) FORWARD. 51 to 3 ........ If no voltage (12 Vdc), defective conveyor switch. 80 to 3 ........ Voltage should vary from 6.5 to 9 Vdc as conveyor feed sensor shaft is rotated. If voltage does not vary, check feed sensor pot for resistance: Pin E to C... 1000 ±100 ohms at all times. Pin C to D .. Ohms should vary as speed pot is rotated. Pin D to E .. Ohms should vary as speed pot is rotated. 83 to 3 ........ If no voltage, defective conveyor speed module.

Automatic Feed & Grade Control

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RH Conveyor Auto Mode Grayhound Analog Display Main Keyswitch

1

1

12 VDC 0

Control 46 15 A

46

3

Brake

Note: Closed in forward (travel control) 34 47

Engage

'A' Release RH Conveyor Auto 47 Off Man 56

46

Remote Feed Override 'D' Stop

46

Forward L.S.

47

RH Feed Control Feed Sensor 53

(C)

(D)

3

(E)

3

90 53

(7)

94

Man. B CW Conv. 95 (2) (8) C Adjust. Speed 54 (1) Speed (10) 96 A 1K 3 3 (5) Module (11) RH Feed Servo (6) 'D' 97 3 46 B A (4) 93 (12) (3)

(9)

56

Stop

RH CONVEYOR DOES NOT RUN IN AUTO MODE Main key switch ON, engine RUNNING, control circuit breaker SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. RH conveyor switch to AUTO, brakes RELEASED, travel lever(s) FORWARD. 53 to 3 ........ If no voltage (12 Vdc), defective conveyor switch. 90 to 3 ........ Voltage should vary from 6.5 to 9 Vdc as conveyor feed sensor shaft is rotated. If voltage does not vary, check feed sensor pot for resistance: Pin E to C... 1000 ±100 ohms at all times. Pin C to D .. Ohms should vary as speed pot is rotated. Pin D to E .. Ohms should vary as speed pot is rotated. 93 to 3 ........ If no voltage, defective conveyor speed module.

Automatic Feed & Grade Control

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LH Conveyor Adjustment Procedure Grayhound Analog Display

52 55 51 83

R2

R1

R3

MAX

MIN

LIMIT

80 85 84 86 3 46

LH CONVEYOR SPEED ADJUSTMENT PROCEDURE (1) Start engine and warm hydraulics to running temperature. Set engine to FULL THROTTLE. (2) Put LH conveyor switch to MANUAL and LH conveyor speed dial to MINIMUM. (3) Adjust minimum speed pot on LH proportional module until auger creeps, then turn counterclockwise until auger ceases to turn. (4) LH conveyor speed dial to MAXIMUM. (5) Adjust limit pot on LH proportional module until auger turns at 135-150 RPM. (6) LH conveyor speed dial to MINIMUM. Auger should stop turning just as dial hits MINIMUM. If not, repeat step 3. (7) If adjustment was needed in step 6, repeat steps 4 and 5. (8) LH conveyor speed dial should be set for 8.3 Vdc from 85 to 3. (9) Adjust MAX pot on LH proportional module until auger turns at 135-150 RPM. (10) LH manual conveyor speed dial to MINIMUM. Conveyor should stop.

Automatic Feed & Grade Control

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A Terex Company

RH Conveyor Adjustment Procedure Grayhound Analog Display

54 56 53 93

R2

R1

R3

MAX

MIN

LIMIT

90 95 94 96 3 46

RH CONVEYOR SPEED ADJUSTMENT PROCEDURE (1) Start engine and warm hydraulics to running temperature. Set engine to FULL THROTTLE. (2) RH conveyor in MANUAL and RH conveyor speed dial to MINIMUM. (3) Adjust minimum speed pot on RH proportional module until auger creeps, then turn counterclockwise until auger ceases to turn. (4) RH conveyor speed dial to MAXIMUM. (5) Adjust limit pot on RH proportional module until auger turns at 135-150 RPM. (6) RH conveyor speed dial to MINIMUM. Auger should stop turning as dial hits MINIMUM. If not repeat step 3. (7) If adjustment was needed in step 6, repeat steps 4 and 5. (8) RH conveyor speed dial should be set for 8.3 Vdc from 95 to 3. (9) Adjust MAX pot on RH proportional module until auger turns at 135-150 RPM. (10) RH manual conveyor speed dial to MINIMUM. Conveyor should stop.

Automatic Feed & Grade Control

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LH Automatic Screed Control Grayhound Analog Display Main Keyswitch 1 1

12 VDC

3

0 Control 46 15A

NOTE: Closed in forward (travel control) 34 47

Brake Engage 34 'A' Release

Forward L.S.

LH Automatic Screed Control 47 46

Auto Set

Mat Thickness 152 155 157 155 157

Man INC 150

DEC

155 157

A B C D E F G

3 155 157

Raise Sol.

Lower Sol.

3

3

H I J

AUTOMATIC SCREED CONTROL The automatic screed control system will operate either in MANUAL or AUTOMATIC modes. A manual/setup/auto switch is used to select the desired mode of operation. If set in MANUAL, the pull point cylinders can be moved up or down by pressing the increase/decrease switch. If set in SETUP, the grade or slope control will be active all the time. This position is used to set up and NULL the sensor. If set in AUTO, the grade or slope control will only be active when the paver is moved forward. TOW POINT CYLINDER DOES NOT RAISE OR LOWER IN MANUAL Main key switch ON, engine RUNNING, control circuit breaker SET. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. Manual/setup/auto switch in MANUAL. Press the manual override buttons on the ends of the solenoid valve. If the cylinder fails to move in both directions refer to the hydraulic troubleshooting section. Increase/decrease switch to INCREASE Check DIN connector for light. If on, defective solenoid. 150 to 3 ...... If no voltage, defective manual/setup/auto switch. 155 to 3 ...... If no voltage, defective increase/decrease switch. If voltage, defective DIN connector. Increase/decrease switch to DECREASE. Check DIN connector for light. If on, defective solenoid. 150 to 3 ...... If no voltage, defective manual/setup/auto switch. 157 to 3 ...... If no voltage, defective increase/decrease switch. If voltage, defective DIN connector. Automatic Feed & Grade Control

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LH Automatic Screed Control Grayhound Analog Display TOW POINT CYLINDER DOES NOT RAISE OR LOWER IN AUTO MODE Test in MANUAL. If tow point cylinder moves in both directions, the problem is not with the solenoid or hydraulic systems. Block tires. Set the following controls: Release BRAKES, set paver speed to 0, push travel lever FORWARD. (Test one lever at a time on track machines) 47 to 3 ........ If no voltage, defective forward limit switch. Manual/setup/auto switch to AUTO. Connect the grade sensor to the left connection point of the burner control console. 152 to 3 ...... If no voltage, defective manual/setup/auto switch. If voltage, defective grade controller. Exchange controllers to confirm. SLOPE CONTROL The grade and slope amplifier modules are interchangeable. To isolate the cause of a problem, try exchanging modules. Make sure the grade/slope switch on the module is set properly. (to SLOPE if module is used in the slope box and to GRADE if module is used in grade sensor.) The remote slope hand set is powered by a 9 volt battery. If this battery gets low, the letters LO BAT appear in the readout window. Replace the battery. If the battery goes dead, the slope control system will function properly; information in the window will not be available

Automatic Feed & Grade Control

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A Terex Company

RH Automatic Screed Control Grayhound Analog Display Main Keyswitch 1 1

12 VDC

3

0 Control 46 15A

NOTE: Closed in forward (travel control) 34 47

Brake Engage 34 Release 'A'

Forward L.S.

RH Automatic Screed Control 47 46

Auto Set

Mat Thickness 162 165 167 167 165

Man INC 160

DEC

165 167

A B C D E F G

3 165 167

Raise Sol.

Lower Sol.

3

3

H I J

AUTOMATIC SCREED CONTROL The automatic screed control system will operate either in MANUAL or AUTOMATIC modes. A manual/setup/auto switch is used to select the desired mode of operation. If set in MANUAL, the pull point cylinders can be moved up or down by pressing the increase/decrease switch. If set in SETUP, the grade or slope control will be active all the time. This position is used to set up and NULL the sensor. If set in AUTO, the grade or slope control will only be active when the paver is moved forward. TOW POINT CYLINDER DOES NOT RAISE OR LOWER IN MANUAL Main key switch ON, engine RUNNING, control circuit breaker SET. Press the manual override buttons on the ends of the solenoid valve. If the cylinder fails to move in both directions refer to the Hydraulic Troubleshooting section. 1 to 3 .......... If no voltage, defective main key switch. 46 to 3 ........ If no voltage, defective control circuit breaker. Manual/setup/auto switch in MANUAL. Increase/decrease switch to INCREASE. Check DIN connector for light. If ON, defective solenoid. 160 to 3 ...... If no voltage, defective manual/setup/auto switch. 165 to 3 ...... If no voltage, defective increase/decrease switch. If voltage, defective DIN connector. Increase/decrease switch to DECREASE. Check DIN connector for light. If on, defective solenoid. 160 to 3 ...... If no voltage, defective manual/setup/auto switch. 167 to 3 ...... If no voltage, defective increase/decrease switch. If voltage, defective DIN connector. Automatic Feed & Grade Control

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RH Automatic Screed Control Grayhound Analog Display TOW POINT CYLINDER DOES NOT RAISE OR LOWER IN AUTO MODE Test in MANUAL. If tow point cylinder moves in both directions, the problem is not with the solenoid or hydraulic systems. Block tires and set the following controls: Release BRAKES, set paver speed to 0, push the travel lever FORWARD. (Test one lever at a time on track machines) 47 to 3 ........ If no voltage, defective forward limit switch. Manual/setup/auto switch to AUTO. Connect the grade sensor to the left connection point of the burner control console. 162 to 3 ...... If no voltage, defective manual/setup/auto switch. If voltage, defective grade controller. Exchange controllers to confirm. SLOPE CONTROL The grade and slope amplifier modules are interchangeable. To isolate the cause of a problem, try exchanging modules. Make sure the grade/slope switch on the module is set properly. (to SLOPE if module is used in the slope box and to GRADE if module is used in grade sensor.) The remote slope hand setter is powered by a 9 volt battery. If this battery gets low, the letters LO BAT appear in the readout window. Replace the battery. If the battery goes dead, the slope control system will function properly; information in the window will not be available

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Generation III Sonics 1st Generation Controls Grayhound Pavers

LH Conveyor - Generation III Sonics

RH Conveyor - Generation III Sonics

For Generation III Sonic troubleshooting, refer to operation manual form 20576 in this section.

Automatic Feed & Grade Control

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Generation III Sonics 2nd Generation Controls Grayhound Pavers

LH Conveyor - Generation III Sonics

RH Conveyor - Generation III Sonics

For Generation III Sonic troubleshooting, refer to operation manual form 20576 in this section.

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Generation III Sonics Conveyor Control 3rd Generation Controls Grayhound Pavers 1999 & After

Automatic Feed & Grade Control

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Generation III Sonics Conveyor Control 3rd Generation Controls Grayhound Pavers 1999 & After GEN. III CONVEYOR CONTROL WITH SINGLE INTERFACE MODULE There are 5 relays used with this type control: One used for Automatic Mode 1/2 of relay for LH 1/2 of relay for RH One used for LH Run One used for RH Run One used for LH Override One used for RH Override Use the following table to test controls. Note: If NO 12 VDC voltage, check appropriate wiring and switches. Conveyor Side

Wires

Voltage

Comment

Automatic Operation Mode

LH

RH

47...3 51...3 80...3 83...3 87...3

12VDC 12VDC 0-2VDC 0-2VDC 0-2VDC

47...3 53...3 90...3 93...3 97...3

12VDC 12VDC 0-2VDC 0-2VDC 0-2VDC

Forward Direction Console in Auto Mode Voltage Readings for 0 to Full Speed

Manual Operation Mode

LH

RH

51...3 81...3 83...3 87...3

12VDC 0-2VDC 0-2VDC 0-2VDC

53...3 91...3 93...3 97...3

12VDC 0-2VDC 0-2VDC 0-2VDC

Forward Direction Console in Manual Mode Voltage Readings for 0 to Full Speed

Override Mode

LH

RH

Automatic Feed & Grade Control

51...3 52...3 83...3 87...3

12VDC 12VDC 2VDC 2VDC

53...3 54...3 93...3 97...3

12VDC 12VDC 2VDC 2VDC

Forward Direction Switches in Override Voltage Readings for Full Speed Only

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Amplifier Module Grade Systems Not used when in grade sensor

Cable to Burner Console plugs in here

RUN

STAND BY

RUN

STAND BY

Deadband Set Point

The same amplifier is used in the GRADE and SLOPE. The only difference is the setting of the SLOPE/ GRADE toggle switch located on the back of the unit.

Down Light

Up Light

Side View

Back View

GRADE

Slope/Grade Toggle Switch SLOPE

AMPLIFIER MODULE The same amplifier module is used in the GRADE and SLOPE units. The only difference is the setting of the Grade/Slope toggle switch located on the back side of the amplifier module. If the unit is to be used in the grade sensor, set the grade/slope switch to GRADE. If the unit is to be used in the slope system, set the grade/slope switch to SLOPE. GRADE OR SLOPE NOT WORKING Perform all checks listed in Electrical Automation section. Inspect all cables and connections for damage. Set manual/setup/auto switch to SETUP, set standby/run switch to RUN. Disconnect large cable from the amplifier. Check pins A to B on cable, voltage should be 11 Vdc or more. If low or no voltage, refer to electrical automation for checking machine wiring. Plug cable back in. With the up light ON, check voltage on: 155 to 3 (for LH pull point), 165 to 3 (for RH pull point) for 12 Vdc. With the down light ON, check voltage on: 157 top 3 (for LH pull point), 167 to 3 (for RH pull point) for 12 Vdc. If no voltage, take an amplifier out of a unit that is known to be functioning properly and install it in the system in question. (Make sure the slope/grade switch is set for the unit to be used in.) If the problems disappear, defective amplifier. Automatic Feed & Grade Control

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Amplifier Module Slope Systems Remote slope hand set plugs in here

Clockwise Light

RUN

Deadband Set Point

CounterClockwise Light

RUN

STAND BY

Side View

STAND BY

Back View

Cable to Burner Console plugs in here

GRADE

Slope/Grade Toggle Switch SLOPE

AUTOMATION NOT WORKING PROPERLY Inspect cables and connections for damage. Check deadband setting on amplifier. The correct deadband setting for the slope amplifier is 0.2 light to light. The correct setting for the grade is: Passing a .050 feeler gauge under the wand or shoe will not show a light, but passing a .080 feeler gauge under the wand or shoe will show a light. Refer to Operation Manual for procedure on setting deadband. Check the Grade/Slope switch located on the back side of the amplifier. It must be in the GRADE position if amplifier is used in the grade sensor and set to SLOPE if used in the slope system. If slope system is in question, refer to Remote Slope Hand Set. Check pull point solenoid valve DIN connectors for light, refer to electrical Pull Point. Take an amplifier out of a unit that is known to be functioning properly and install it in the system in question. (Make sure the Slope/Grade switch is set for the unit to be used in.) If the problems disappear, defective amplifier. LIGHT BULB REPLACEMENT Unscrew the lens cover over the light bulb. Take a piece of 5¦16" ID rubber hose and press down and turn bulb counterclockwise. The bulb can be purchased at most local vendors as #161 (12 Vdc) bulb.

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Remote Slope Set

9 Volt

WHEN DISPLAY SHOWS "LOW BAT" REPLACE 9 VOLT BATTERY

BATTERY LOCATION

NO DISPLAY Check harness and connectors for damage. Check battery, replace as necessary. Check pins A to C on the slope amplifier (the unit the remote set plugs into). Voltage should be at least 2.1 Vdc. If voltage is OK, defective remote slope hand set. If no or low voltage, unplug the harness coming from the burner console to the slope amplifier. Check pins A to B on the socket end. Voltage should be 11 Vdc or more. If voltage, defective amplifier. If no or low voltage, refer to automation. DISPLAY STAYS ON EVEN WHEN UNPLUGGED Replace remote slope hand set unit. SLOPE APPEARS TO BE UNSTABLE OR OSCILLATES Check deadband setting on the slope amplifier. The proper setting is 0.2 light to light. If deadband is OK, unplug remote hand set and check pins B to D. 1500 ohms should be read. If a reading shows 500 ohms, a capacitor is shorted. Replace unit. Check pins A to C for 2500 ohms. Then check for continuity between pins A to B and pins B to C, while rotating the dial. The reading should vary as the dial is turned. If another remote slope hand set unit is available, connect it in place of existing one. If problem disappears, defective remote hand set. Automatic Feed & Grade Control

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Slope Sensor Checks

SLOPE SENSOR CHECKS Check Ohms between pins. A to B......... 10 ohms. C to D ........ 300 ohms. E to F ......... 300 ohms. No cross continuity.

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System 4 LH Automatic Screed Control Grayhound Pavers 1999 & Before

L.H. AUTOMATIC SCREED CONTROL 47

MAT THICKNESS AUTO SET

46

152

L.H. AUTO ISOLATION RELAY 14

LAI

3

13

MAN 152

INC 155B 150 DEC 157B 157B

150 46

3 155B A B C D E F G H I J

3 46 155A 157A 155A 157A

3 4

155A

5

9

8

12

157A

1

155

B SOL.

3

157

A SOL.

3

10 PIN RECPTACLE FOR AUTO CABLE

PROPER OPERATION Refer to System 4 operation manual, Form 21048, in the Automatic Grade & Feed Controls section of this manual for additional information. Proper operation of the System 4 Control System occurs when: Controls power-up whenever paver is in Run and Grade or Slope is selected. Valves become "live" when Mat Thickness mode switch on LH Screed Remote box is either in Setup or when in Auto and paver is moving Forward. Manual Up-Down on System 4 will work only when valves are "live". This is accomplished by modifying the tractor wiring from standard by adding Isolation Relays.

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System 4 LH Automatic Screed Control Grayhound Pavers 1999 & Before TOW POINT CYLINDER DOES NOT RAISE OR LOWER IN MANUAL Man-Setup-Auto switch in Manual. Press Manual Override button on solenoid valve; If Nonfunctional, refer to Hydraulic Troubleshooting. If Functional, proceed below. Check DIN connector on valve for light; If light is ON, check for 12 VDC across solenoid coil (pin 1 to pin 2); If no voltage, check connection of DIN connector. If voltage, check and/or replace solenoid coil. If No Light; Check for 12 VDC from 155 to 3 with switch in Increase, 157 to 3 with switch in Decrease. If no voltage, check 155B to 3 in Increase, 157B to 3 in Decrease. If voltage, check 152 to 3. Should not have any voltage. Replace Man-Setup-Auto switch if voltage present. Replace Isolation Relay if no voltage. If NO voltage, check 150 to 3; If voltage, replace Increase-Decrease switch. If NO voltage, check/replace Man-Setup-Auto switch. If voltage, check wiring to valves. SYSTEM 4 CONTROL DOES NOT RAISE OR LOWER TOW POINT IN MANUAL OR AUTO If System 4 control will NOT power up when Grade or Slope is selected; Check for 12 VDC from 46 to 3 in Main Screed Box. If NO voltage, check wiring from Tractor. If voltage, check for 12 VDC from pin F to pin K at Controller power cable. If NO voltage, check wiring from Main Screed Box. If voltage, proceed to System 4 Troubleshooting. If System 4 control powers up when Grade or Slope is selected but valves will not operate; Check for 12 VDC from 155A for UP, 157A for DOWN; If NO voltage, proceed to System 4 Troubleshooting. If voltage, check for 12 VDC from 155 for UP, 157 for DOWN; If voltage, check wiring to valves. If NO voltage, check 152 to 3. If voltage, check Isolation Relay by switching with RH Relay. Replace if defective. If NO voltage, check/replace Man-Setup-Auto switch.

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System 4 LH Automatic Screed Control Grayhound Pavers 1999 & After

PROPER OPERATION Refer to System 4 operation manual, Form 21048, in the Automatic Grade & Feed Controls section of this manual for additional information. Proper operation of the System 4 Control System occurs when: Controls power-up whenever paver is in Run and Grade or Slope is selected. Valves become "live" when Mat Thickness mode switch on LH Screed Remote box is either in Setup or when in Auto and paver is moving Forward. Manual Up-Down on System 4 will work only when valves are "live". This is accomplished by modifying the tractor wiring from standard by adding Isolation Relays.

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System 4 LH Automatic Screed Control Grayhound Pavers 1999 & After TOW POINT CYLINDER DOES NOT RAISE OR LOWER IN MANUAL Man-Setup-Auto switch in Manual. Press Manual Override button on solenoid valve; If Nonfunctional, refer to Hydraulic Troubleshooting. If Functional, proceed below. Check DIN connector on valve for light; If light is ON, check for 12 VDC across solenoid coil (pin 1 to pin 2); If no voltage, check connection of DIN connector. If voltage, check and/or replace solenoid coil. If No Light; Check for 12 VDC from 155 to 3 with switch in Increase, 157 to 3 with switch in Decrease. If no voltage, check 155 to 3 in Increase, 157 to 3 in Decrease. If voltage, check 152 to 3. Should not have any voltage. Replace Man-Setup-Auto switch if voltage present. Replace Isolation Relay if no voltage. If NO voltage, check 150 to 3; If voltage, replace Increase-Decrease switch. If NO voltage, check/replace Man-Setup-Auto switch. If voltage, check wiring to valves. CONTROL DOES NOT RAISE OR LOWER TOW POINT IN MANUAL OR AUTO If System 4 control will NOT power up when Grade or Slope is selected; Check for 12 VDC from 46 to 3 in Main Screed Box. If NO voltage, check wiring from Tractor. If voltage, check for 12 VDC from pin F to pin K at Controller power cable. If NO voltage, check wiring from Main Screed Box. If voltage, proceed to System 4 Troubleshooting. If System 4 control powers up when Grade or Slope is selected but valves will not operate; Check for 12 VDC from 155A for UP, 157A for DOWN; If NO voltage, proceed to System 4 Troubleshooting. If voltage, check for 12 VDC from 155 for UP, 157 for DOWN; If voltage, check wiring to valves. If NO voltage, check 152 to 3. If voltage, check Isolation Relay by switching with RH Relay. Replace if defective. If NO voltage, check/replace Man-Setup-Auto switch.

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System 4 RH Automatic Screed Control Grayhound Pavers 1999 & Before

R.H. AUTOMATIC SCREED CONTROL 47

46

MAT THICKNESS R.H. AUTO ISOLATION AUTO 13 14 SET 162 RAI MAN 162

RELAY 3

INC 165B 160

160 46

DEC 167B 167 B 165B

A 3 46 4 1 B 165A C 12 167A 165A 8 B SOL. 165 D 167A 167A E 167 A SOL. 165A F 5 9 G H I 10 PIN RECEPTACALE FOR AUTO CABLE J

3

3 3

PROPER OPERATION Refer to System 4 operation manual, Form 21048, in the Automatic Grade & Feed Controls section of this manual for additional information. Proper operation of the System 4 Control System occurs when: Controls power-up whenever paver is in Run and Grade or Slope is selected. Valves become "live" when Mat Thickness mode switch on RH Screed Remote box is either in Setup or when in Auto and paver is moving Forward. Manual Up-Down on System 4 will work only when valves are "live". This is accomplished by modifying the tractor wiring from standard by adding Isolation Relays.

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System 4 RH Automatic Screed Control Grayhound Pavers 1999 & Before

TOW POINT CYLINDER DOES NOT RAISE OR LOWER IN MANUAL Man-Setup-Auto switch in Manual. Press Manual Override button on solenoid valve; If Nonfunctional, refer to Hydraulic Troubleshooting. If Functional, proceed below. Check DIN connector on valve for light; If light is ON, check for 12 VDC across solenoid coil (pin 1 to pin 2); If no voltage, check connection of DIN connector. If voltage, check and/or replace solenoid coil. If No Light; Check for 12 VDC from 165 to 3 with switch in Increase, 167 to 3 with switch in Decrease. If no voltage, check 165B to 3 in Increase, 167B to 3 in Decrease. If voltage, check 162 to 3. Should not have any voltage. Replace Man-Setup-Auto switch if voltage present. Replace Isolation Relay if no voltage. If NO voltage, check 160 to 3; If voltage, replace Increase-Decrease switch. If NO voltage, check/replace Man-Setup-Auto switch. If voltage, check wiring to valves. SYSTEM 4 CONTROL DOES NOT RAISE OR LOWER TOW POINT IN MANUAL OR AUTO If System 4 control will NOT power up when Grade or Slope is selected; Check for 12 VDC from 46 to 3 in Main Screed Box. If NO voltage, check wiring from Tractor. If voltage, check for 12 VDC from pin F to pin K at Controller power cable. If NO voltage, check wiring from Main Screed Box. If voltage, proceed to System 4 Troubleshooting. If System 4 control powers up when Grade or Slope is selected but valves will not operate; Check for 12 VDC from 165A for UP, 167A for DOWN; If NO voltage, proceed to System 4 Troubleshooting. If voltage, check for 12 VDC from 165 for UP, 167 for DOWN; If voltage, check wiring to valves. If NO voltage, check 162 to 3. If voltage, check Isolation Relay by switching with LH Relay. Replace if defective. If NO voltage, check/replace Man-Setup-Auto switch.

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System 4 RH Automatic Screed Control Grayhound Pavers 1999 & After

PROPER OPERATION Refer to System 4 operation manual, Form 21048, in the Automatic Grade & Feed Controls section of this manual for additional information. Proper operation of the System 4 Control System occurs when: Controls power-up whenever paver is in Run and Grade or Slope is selected. Valves become "live" when Mat Thickness mode switch on RH Screed Remote box is either in Setup or when in Auto and paver is moving Forward. Manual Up-Down on System 4 will work only when valves are "live". This is accomplished by modifying the tractor wiring from standard by adding Isolation Relays.

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System 4 RH Automatic Screed Control Grayhound Pavers 1999 & After

TOW POINT CYLINDER DOES NOT RAISE OR LOWER IN MANUAL Man-Setup-Auto switch in Manual. Press Manual Override button on solenoid valve; If Nonfunctional, refer to Hydraulic Troubleshooting. If Functional, proceed below. Check DIN connector on valve for light; If light is ON, check for 12 VDC across solenoid coil (pin 1 to pin 2); If no voltage, check connection of DIN connector. If voltage, check and/or replace solenoid coil. If No Light; Check for 12 VDC from 165 to 3 with switch in Increase, 167 to 3 with switch in Decrease. If no voltage, check 165 to 3 in Increase, 167 to 3 in Decrease. If voltage, check 162 to 3. Should not have any voltage. Replace Man-Setup-Auto switch if voltage present. Replace Isolation Relay if no voltage. If NO voltage, check 160 to 3; If voltage, replace Increase-Decrease switch. If NO voltage, check/replace Man-Setup-Auto switch. If voltage, check wiring to valves. CONTROL DOES NOT RAISE OR LOWER TOW POINT IN MANUAL OR AUTO If System 4 control will NOT power up when Grade or Slope is selected; Check for 12 VDC from 46 to 3 in Main Screed Box. If NO voltage, check wiring from Tractor. If voltage, check for 12 VDC from pin F to pin K at Controller power cable. If NO voltage, check wiring from Main Screed Box. If voltage, proceed to System 4 Troubleshooting. If System 4 control powers up when Grade or Slope is selected but valves will not operate; Check for 12 VDC from 165A for UP, 167A for DOWN; If NO voltage, proceed to System 4 Troubleshooting. If voltage, check for 12 VDC from 165 for UP, 167 for DOWN; If voltage, check wiring to valves. If NO voltage, check 162 to 3. If voltage, check Isolation Relay by switching with LH Relay. Replace if defective. If NO voltage, check/replace Man-Setup-Auto switch.

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Remix Delivery Control All Grayhound Pavers

1 3

2

5

6

4

FEED INTERFACE MODULE

K3 K4 K5

SP

AR

E

K6

Delivery Control Components 4) Ratio Pot: Sends 0.5 - 4.5 VDC signal to controller.

1) Controller W/Ind. Lights: Programmed to process electrical signals coming from speed and pressure sensors and ratio pot, then output signals to feed interface module. Indicator lights provide troubleshooting assistance.

5) Speed Sensor: Located on spreading auger motor and provides pulse signal to controller to allow AUTO operation.

2) Feed Interface Module: Provides a relay contact between controller output and spreading auger pump EDC coil. This relay pulls in via AUTO-OFF-MANUAL Switch.

6) Pressure Sensor: Located on rear bulkhead in delivery auger motor pressure circuit and provides 0.5 - 4.5 VDC to controller indicating 0 to 10,000 PSI of hydraulic pressure. a) 0.5 VDC @ 0 PSI b) 2.5 VDC @ 5000 PSI c) 4.5 VDC @ 10,000 PSI

3) AUTO-OFF-MANUAL Switch: Sends 12 VDC signal to controller to select mode of operation.

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Remix Delivery Control All Grayhound Pavers Remix Delivery Control Operation AUTO-OFF-MANUAL Switch in MANUAL

If replacement of a controller becomes necessary, simply remove the old one and plug in the new one. No adjustment is needed.

1) Ratio dial operates strictly as a speed control. 2) Operates whether spreading augers ore ON or OFF.

Refer to the electrical schematic supplied with your machine and the following information to assist in troubleshooting this system. Also, the chart below gives a guide to reading the status of the indicator lights on the controllers.

3) Pressure sensor on delivery auger motor is active and will limit horsepower when needed. AUTO-OFF-MANUAL Switch in AUTO

1) Controller: Sensor power output wire 284 (LH) and 294 (RH) should have 5 VDC. If low voltage, check for defective sensor, ratio pot, or grounded wiring.

1) Ratio dial setting determines the speed of the delivery augers in relation to the spreading auger speed. (0 - 100% of spreading auger speed range)

2) Ratio Pot: Provides range of 0.5 to 4.5 VDC to controller. a) 0.5 VDC at MIN b) 2.5 VDC at 50% dial setting c) 4.5 VDC at MAX

2) Delivery augers start and stop with spreading augers no matter what mode the spreading augers are operating. (MANUAL, AUTO, or OVERRIDE) 3) Delivery auger speed is based on spreading auger speed and ratio setting.

3) AUTO-OFF-MANUAL Switch: Provides 12 VDC to controller to select mode of operation and supplies power to the controller eliminating need for feed interface module on valve output.

4) Set ratio dial to maintain a uniform head of material (one half auger level).

4) Speed Sensor: Located on spreading auger motor, provides pulse signal to controller to allow AUTO operation.

5) Spreading auger RPM should remain constant with this setting. 6) Pressure sensor on delivery auger motor is active and will limit horsepower when needed.

5) Pressure Sensor: Located on rear bulkhead in delivery auger motor pressure circuit, provides a range of 0.5 to 4.5 VDC to controller. a) 0.5 VDC at 0 PSI b) 0.7 VDC at 500 PSI c) 0.9 VDC at 1000 PSI d) 2.5 VDC at 5000 PSI e) 4.5 VDC at 10,000 PSI

Remix Delivery Control Troubleshooting The delivery augers are controlled by the remix feed controllers mounted in the main electrical box. (See previous page) Automatic Feed & Grade Control

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Remix Delivery Control All Grayhound Pavers

INDICATOR COLOR LIGHT POWER

LIGHT STATUS

ERROR CODE

ERROR DESCRIPTION

Power

Green

On Solid

N/A

Indicates Power to Controller

System

Green

On Solid

N/A

Indicates +5 VDC Out of Controller

Mode

Yellow

Blinking

1 Blink / 2 Seconds

Program is Running OK

Mode

Yellow

Blinking

10 Blinks / 1 Second

Controller Needs Replaced (No Program Loaded)

SYSTEM MODE STATUS

Mode

Status

Program Not Running Not Blinking Light Completely Off Cycle Power Off and back On Yellow (If problem still exists, replace On or Off or On Solid controller) Pressure signal out of range Red Blinking 1110 (defective wiring or sensor)

Status

Red

Blinking

0100

Status

Red

Blinking

0110

Ratio Pot signal out of range (defective wiring or speed pot) Spreading Auger not running or defective wiring or speed sensor

Status Indicator Light Code Legend: Short Blink = 0 Long Blink = 1

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Remix Delivery Control Re-Work Kit Wiring Diagram 9704-417-20

LH

Automatic Feed & Grade Control

RH

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Remix Delivery Control Re-Work Kit Installation Instructions 9704-417-21

Automatic Feed & Grade Control

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Remix Delivery Control Re-Work Kit Installation Instructions 9704-417-21

Automatic Feed & Grade Control

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Remix Delivery Control Re-Work Kit Installation Instructions 9704-417-21

Automatic Feed & Grade Control

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Remix Delivery Control Re-Work Kit Installation Instructions 9704-417-21

Automatic Feed & Grade Control

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Automatic Feed & Grade Control

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Generation III Sonic Feeder Control System

Operation & Maintenance Instructions

Generation III Sonic Feeder Control System

A Terex Company

20576 (11/00)

49999-176

Operation & Maintenance Manual

A Terex Company

Introduction

To the Owner & Operator: We have tried to provide information which will give you a clear understanding of equipment construction, function, capabilities and requirements. This information is based on the knowledge and experience of highly qualified people at our company and in our field organization. Proper use of this information will promote high efficiency, maximum service life and low maintenance costs. We strongly recommend that all persons directly involved with this equipment be familiar with this manual. The information contained in this manual should not be considered all-inclusive for every application. Questions about specific uses of this equipment should be directed to Cedarapids Inc. Anyone who uses this equipment for any purposes other than its intended use assumes the risk of any danger in doing so. Respectfully, Cedarapids Inc.

Important Notice! Federal, state and local safety regulations must be complied with to prevent possible danger to person(s) or property from accidents or harmful exposure. This equipment must be used in accordance with all operation and maintenance instructions. (1)

Read all warning, caution and instruction signs. Know what guards and protective devices are included and see that each is used. Additional guards and protective devices that may be required due to proximity to related equipment must be installed by the user (owner) before operating.

(2)

Never lubricate or adjust equipment when it is operating!

(3)

Securely lock out the involved power source before doing maintenance, cleaning, adjusting or repair. Secure the power source lockout to prevent start-up by other persons.

(4)

Wear a protective mask whenever harmful air pollution exists.

(5)

Use ear plugs whenever noise level is above established limits.

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Safety Safety Rules When operating this equipment, always follow the safety rules. Cedarapids makes no guarantee either expressed or implied that the equipment meets all local or federal safety regulations. It is the responsibility of the individual user to verify that all safety regulations are complied with before starting the machine.

• We strongly recommend that all persons involved with this equipment be familiar with this manual and all related engine manuals. • Read all Danger, Warning, Caution and instruction decals. • Know what guards and protective devices are included and see that each is used.

Personal Safety Rules Cedarapids equipment is designed to operate safely when used responsibly and as instructed in the operation manuals. Do not attempt to change, modify or eliminate the accident prevention devices installed at the factory. Make sure all personnel who regularly work or who might do work in the area of the equipment are familiar with the safety precautions. Operators are responsible for following safe operating procedures. It is the responsibility of the owner to establish a safe working environment and to train the employees on the employers safety policies

Hazard Seriousness Level Signal words (Danger, Warning and Caution) are used to identify levels of hazard seriousness in this manual and on decals located on the equipment. Definitions for identifying hazard levels are provided below with their respective signal words. Danger! Immediate hazards which WILL result in severe personal injury or death. Warning! Hazards or unsafe practices which COULD result in severe personal injury or death.

Guards, covers and shields are installed around moving parts at the factory whenever necessary to prevent accidental injury to operators and others working on or near the equipment. Do not remove them. In come cases the owner may need to install additional guarding and safety systems to protect the operator.

Caution! Hazards or unsafe practices which COULD result in minor personal injury. Instructional and Informational Levels Signal words are used to identify instructional procedures and informational suggestions or directions for Cedarapids equipment operation and maintenance.

Warning! This manual contains important information regarding the operation of your machine. Carefully read the entire manual before attempting to operate. Failure to read this manual and follow the instructions and warnings in it could cause severe personal injury, death or substantial property damage.

Definitions for identifying instructional or informational levels are provided below. Notice: Failure to follow proper instructional procedures could lead to serious and/or expensive damage to the equipment. Important: Informational suggestions or directions regarding operational and maintenance of equipment.

• Only qualified and trained persons should operate, repair or maintain this equipment. • Keep this manual for future reference. • Federal, state and local safety regulations must be complied with to prevent possible danger to person(s) or property from accidents or harmful exposure. • This equipment must be used in accordance with all operation and maintenance instructions. 20576 (11/00)

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Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Safety Warning! Failure to follow these guidelines may result in severe personal injury or death.

Caution! Failure to follow these guidelines may result in minor personal injury and/or damage to the equipment.

• Never attempt to install or remove any part or assembly when the paver is running.

• Wear protective mask when harmful air pollution exists.

• Do not allow personnel to walk between the machine and truck.

• Wear safety goggles, gloves and long-sleeve shirts when in close proximity to hot asphalt materials.

• Do not refuel the machine with the engine running. All sparks and open flames must be kept a minimum of 50 feet away from the machine when refueling.

• Wear ear plugs if needed. • To prevent fire hazards, keep the engine area free of oil, fuel and trash buildup .

• Wear snug-fitting clothing to prevent getting caught in moving parts. Loose-fitting clothing should never be worn. • Mount and dismount the machine using only the steps, handrails and walkways provided. • Do not mount or dismount the machine when it is moving. • Keep all personnel clear of machine when operating.

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Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Gen-III Feeder Controls Introduction The Gen-III feeder control is an optional control system that uses ultrasonic sensors or proportional sensors to monitor and maintain the head of material in front of the screed. As the material level changes the auger/conveyor speed is varied proportional to maintain the set material level.

LH ADAPTER CABLE 09704-416-25 LH PLATE 09704-416-23

Features of the Gen-III Feeder System 1) The screed mounted control unit allows for easy setup and adjustment of the material level without requiring the screedman to relocate the height of the sensor to meet varying conditions. Once the sensor has been mounted and targeted the material level can be adjusted from the rear of the screed.

POWER CABLE 46061-500-27

SONIC SENSOR 46061-100-20

SENSOR CABLE 46061-100-23

FEEDER CONTROL 46061-100-27

Figure 1

2) The sonic system has detachable sensor and cable assemblies. The cable has connectors on both ends that allow quick replacement in the event a cable is damaged.

Plug one end the power cable into the RH rear bulkhead of the tractor and the other end into the RH feeder control mounted on the screed (Figure 2). This cable can be left connected all the time. Remove the protective cap from the RH side of the feeder control and plug in the coiled sensor cable (Figure 2). Place sonic sensor in the RH end-gate sonic mount and route coiled cable to it. Plug coiled cable into sensor.

3) Standard proportional feeder controls can be plugged into the Gen-III feeder control and used in place of the sonic sensor. Connecting Sonics Sensors 1) Plug one end of the power cable into the LH rear bulkhead of the tractor and the other end into the LH feeder control mounted on the screed (Figure 1). This cable can be left connected all the time.

RH ADAPTER CABLE 09704-416-24 RH PLATE 09704-416-22

2) Remove the protective cap from the LH side of the feeder control and plug in the coiled sensor cable (Figure 1). 3) Place sonic sensor in the LH end-gate sonic mount and route coiled cable to it. Plug coiled cable into sensor.

POWER CABLE 46061-500-27

SENSOR CABLE 46061-100-23

SONIC SENSOR 46061-100-20

FEEDER CONTROL 46061-100-27

Figure 2

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Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Gen-III Feeder Controls Connecting Proportional Sensors 1) Plug one end of the power cable into the LH rear bulkhead of the tractor and the other end into the LH feeder control mounted on the screed (Figure 3). This cable can be left connected all the time.

RH REAR BULKHEAD

PROPORTAIONAL SENSOR 46061-500-24

2) Place proportional sensor on outer auger bearing support or end-gate mount. 3) Remove the protective cap from the LH side of the feeder control and plug in the coiled sensor cable (Figure 3).

Direction of Travel

Figure 4

Wand Mounting Loosen the control arm clamp and position the wand so that the roll pin is at 90° in relation to control arm (Figure 5). Tighten clamp.

Notice: The proportional feed sensor should always be mounted with the sensor shaft facing the direction of travel. LH REAR BULKHEAD

CONTROL ARM CLAMP SENSOR SHAFT

ROLL PIN

PROPORTIONAL SENSOR 46061-500-24

ROLL PIN 90° TO CONTROL ARM WAND

Direction of Travel

Figure 3

Connecting Proportional Sensors 1) Plug one end of the power cable into the RH rear bulkhead of the tractor and the other end into the RH feeder control mounted on the screed (Figure 4). This cable can be left connected all the time.

Figure 5

2) Place proportional sensor on outer auger bearing support or end-gate mount it. 3) Remove the protective cap from the RH side of the feeder control and plug in the coiled sensor cable (Figure 4) Notice: The proportional feeder sensor should always be mounted with the sensor shaft facing the direction of travel.

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Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Controls Feeder Control 1) AUTO/OFF/MANUAL (Item 1, Figure 6) switch is the primary means to control the auger/conveyor. When placed in the OFF position the auger/conveyor is off; when placed in the MANUAL position the auger/conveyor is turned on. The speed of the auger conveyor when in MANUAL is determined by the pile height knob setting. When placed in the AUTO position the auger/conveyor speed is controlled by the feed sensor. In AUTO mode the auger/ conveyor has the capability of being driven from 0 to full speed depending on sensor output.

When proportional sensors are used with the system the GAIN switch sets the amount of rotation required for the sensing wand to go from OFF to full ON. In LOW gain, the wand will react in a 45° control range (Figure 7). In HIGH gain, the want will react in a 22° control range (Figure 7). Normally, the GAIN switch should be set to HIGH when using the proportional sensor. 1

2) The PILE HEIGHT knob performs different functions depending on sensor used and setting of AUTO/OFF/MANUAL switch. It’s used to set the maximum speed of the auger/conveyor when the AUTO/OFF/MANUAL switch is in the MANUAL mode (Item 2, Figure 6).

MODE

3

PILE HEIGHT

AUTO

GAIN HIGH

OFF MANUAL

Another usage is to set the distance from the face of the sonic sensor to the material when the AUTO/OFF/MANUAL switch is placed in the AUTO mode. Turning the knob counterclockwise lowers the material level. Clockwise rotation of the knob increases the material level.

LOW

HIGH

LOW

FEEDER CONTROL 46061-100-27 Figure 6

Finally, it’s used to set the angle at which the proportional sensor shuts off when the AUTO/ OFF/MANUAL switch is placed in the AUTO mode and the proportional sensor is used.

LOW GAIN (45°)

3) GAIN switch must be set in the LOW position when sonic sensors are used with the system (Item 3, Figure 6). When GAIN switch is in LOW, the sonic system controls the speed of the auger/conveyor proportionally within a 5" range. When GAIN switch is in HIGH position the control range is reduced to 2.5". Since the level of the mix can vary by more than 2.5" during normal operation, the sonic control will function like an on/off switch and will not provide proportional control. 20576 (11/00)

2

HIGH GAIN (22°)

Figure 7

5

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Controls Operator Console 1) Left Auger/Conveyor (Item 1, Figure 8) is a two position switch. When the switch is pressed into the STOP position, the auger/conveyor is stopped. When the switch is pressed into the OVERRIDE position the auger/conveyor is turned on.

Remote Handset The Stop/Override (Figure 9) is a two position switch. When the switch is pressed into the STOP position, the auger/conveyor is stopped. When the switch is pressed into the OVERRIDE position the auger conveyor is turned on.

D N TE EX

2) Right Auger/Conveyor (Item 2, Figure 8) is a two position switch. When the switch is pressed into the STOP position, the auger/conveyor is stopped. When the switch is pressed into the OVERRIDE position the auger conveyor is turned on.

PE O SL

T SE P U

ED FE R VE O IDE R

N R O H

OFF SCREED LIFT RAISE

TO AU

P O ST

4) Right Flow Gate switch (Item 4, Figure 8) is used to control the amount of material that is delivered to the auger chamber LIGHTS ON

T H G EI H H P TC U A M

SE EA R EC D AN M

3) Left Flow Gate switch (Item 3, Figure 8) is used to control the amount of material that is delivered to the auger chamber .

S N ES W N O K D IC SE TH EA T R A C M IN

1

FLASHERS ON

Figure 9

OFF REAR FRAME RAISE

LOWER

LOWER

HORN ON

VIBRATORS ON

OFF

OFF

BRAKE RELEASE

ENGINE START

ENGAGE

STOP

SCREED ASSIST ON ENGAGE ONLY WHEN SCREED IS ON OFF GROUND

Item 3 Item 4

GATES RAISE LH

4625-001-09

RH LOWER

MIN

GATES MIN

MAX

MAX

MAX PAVER SPEED 4 3 2

LH THROTTLE FULL

RH CONVEYOR OVER RIDE

RANGE TRAVEL P/2

IDLE

P/4

Item 1 4600-009041

LH

HOPPER RAISE

TRUCK HITCH ENGAGE

1 MIN

5

6 7 8 9 MAX

RH STOP

LOWER

RELEASE

Item 2 4600-009041 4418-804

Figure 8

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6

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Targeting Sonic Sensor Targeting on Active Material The sensor should always be targeted on the material that is actively moving. This area is traditionally on the forward outboard end of the auger (Figure 12). The sensor should be targeted in the center area of the face of material for best results.

The sensor should be mounted in a position that targets the cone shaped field of view of the sensor on the ACTIVE MATERIAL near the outer end of the auger. Sensor Distance The sonic sensor should be no closer than 12 inches and no further than 30 inches away from the face of the material (Figure 10).

Correct

MAXIMUM 30 Inches

MINIMUM 12 Inches

Figure 10

Sonic Sensor Alignment For best possible results the sensor should be targeted perpendicular (90°) to the material surface being monitored. Misalignment decreases the amount of return echo’s to the sensor. The type of material being used determines the amount of misalignment tolerance. Fine graded material designs, like sand mixes, have a low reflective value and require the sensor to be targeted perpendicular while course graded material designs have a high reflective value and may allow up to a 10° misalignment (Figure 11).

Incorrect – Would sense shaft

Figure 12

The most common problem encountered with the use of sonic feeder controls is improper mounting and targeting. The system will react to the object that is inside the view window and closest to the sensor (Figure 12). Care must be taken in mounting and targeting the sensors to prevent sensing objects (end gates, augers, material retaining plates, etc.) other than the desired material level.

90°

Correct Alignment

Incorrect Alignment Figure 11

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7

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Targeting Sonic Sensor Setup & Use of Proportional The following procedure will initially establish the desired material level:

Positioning Proportional Sensor The proportional sensor should be mounted at the outboard end of the auger so the control arm is free to follow the level of material without interference from augers, material retaining plates and end gates. Best results occur when sensing on the active material.

1) Connect the sensor cable to the feed control. 2) Place sensor at the outboard end of the auger. 3) Using the remote handset OVERRIDE/STOP switch or the feed control AUTO/OFF/ MANUAL switch, auger out material until the desired level is established

Correct

4) Place the feed control AUTO/OFF/MANUAL switch in AUTO mode. 5) As the paver start moving adjust the PILE HEIGHT knob until the auger just comes on. 6) Using the GAIN switch can effectively raise or lower the material level. Select the mode that produces the best result.

Figure 13

Setup & Use of Sonic The following steps will initially establish the desired material level.

7) Minor adjustments to the PILE HEIGHT knob can fine tune the level of material that the auger shuts off. Note however the pile height knob has a limited working range (degree of rotation) that the proportional sensor will function in. If The pile height knob is set incorrectly the auger/ conveyor could be either on or off continually.

1) Connect the sensor cable to the sensor and to the feed control. 2) Place sensor in endgate mount and establish preliminary targeting. 3) Using either OVERRIDE/STOP switch or the feed control AUTO/OFF/MANUAL switch, auger out material until the desired level is established

Important: The system will only operate when the traction control lever is in forward and the brakes are released.

4) Place the feed control AUTO/OFF/MANUAL switch in AUTO mode. 5 ) As the paver starts moving adjust the PILE HEIGHT knob until the desired level is maintained. Important: The feed system will only operate in AUTO when the traction control lever is in forward and the brakes are released.

20576 (11/00)

8

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Adjustments for Gen-III Systems Maximum Speed Automatic Mode The following procedure will adjust the maximum speed of the auger in Override mode:

Maximum Speed Manual Override To adjust the maximum speed of the auger in override mode: 1) Engine at full throttle.

1) Engine at full throttle.

2) Press and hold OVERRIDE switch in either the operator console or remote handset to override position.

2) Travel speed dial at 0. 3) Brakes released. 4) Travel lever in forward.

3) Place a tachometer on the end of the auger shaft. The auger should be running between 135 and 150 RPM.

5) Feed control Auto/Off/Manual switch to AUTO. 6) Hold the sonic sensor 4 to 5 feet away from and pointed at the back of the tractor or a truck.

If the auger speed is not within this range, the speed can be adjusted on the conveyor circuit card found in the main electrical junction box on the tractor (Figure 14). The circuit card has three speed adjustments; MAX, MIN and LIMIT. The MIN adjustment is not used with the Gen-III systems. Rotate the MAX adjustment clockwise to increase the auger speed and counterclockwise to decrease the auger speed. If the desired auger speed cannot be reached, rotate the LIMIT adjustment clockwise to increase the upper auger speed limit and continue adjusting the MAX speed adjustment to change the auger speed.

7) Using a tachometer on the end of the auger shaft, adjust the maximum speed set point on the feeder control card located inside the feed control box. The normal setting is 135 to 150 RPM (Figure 15).

IMAX MAX ADJUST Set for desired max speed in AUTO

Warning! Failure to use caution when working near the rotating augers could result in serious injury or death. MAX

C3

TF1

R9 D4

MIN

LIMIT

D3

R12

Figure 15

D2 R11

D7

RLY 1

R5

U1

R16 Q1

C4

RLY 3

MAX

MIN R13

R3

R4 R10

D5

R1

R8 R7

RLY 2

R6 R17

R2 D6

LIMIT D8

R14 MV1

C1

U2

J1

MIN

C2

Figure 14 20576 (11/00)

9

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

20576 (11/00)

10

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Maintenance Maintenance Recommendations 1) Remove sonic sensors every evening and store in a secured location. 2) Install protective caps on all electrical connectors. 3) Handle sonic sensor with care to prevent damage to the transducer. The transducer is made of a ceramic material can be cracked or damaged if impacted.

9704-452-64

Notice: If the transducer becomes damaged it will require replacement of the complete sensor. These are permanently sealed and can not be repaired.

46185-001-20

4) Check transducer daily for material buildup. The transducer can be cleaned off with contact cleaner or a parts solvent. Place cleaning fluid on a clean rag and rub transducer gently to remove any material. Then wipe transducer clean and dry (Figure 16). Do not use a sharp or solid object to scrape materials off. This could possibly damage the sensor.

9704-452-63

Figure 17 Mounting Hardware

Theory of Operation

When cleaning and handling sensor take care not to damage ceramic transducer!

SONIC SENSOR

CLEAN TRANSDUCER OF MATERIAL BUILDUP

Figure 16

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11

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

1st Generation Controls Electrical Schematic LH Feeder System

Figure 18

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12

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

1st Generation Controls Electrical Schematic RH Feeder System

Figure 19

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13

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

2nd Generation Controls Electrical Schematic LH Feeder System

Figure 18a

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14

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

2nd Generation Controls Electrical Schematic RH Feeder System

Figure 19a

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15

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

3rd Generation Controls Grayhound Pavers 1999 & After

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16

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

3rd Generation Controls Grayhound Pavers 1999 & After GEN. III CONVEYOR CONTROL WITH SINGLE INTERFACE MODULE There are 5 relays used with this type control: One used for Automatic Mode 1/2 of relay for LH 1/2 of relay for RH One used for LH Run One used for RH Run One used for LH Override One used for RH Override Use the following table to test controls. Note: If NO 12 VDC voltage, check appropriate wiring and switches. Conveyor Side

Wires

Voltage

Comment

Automatic Operation Mode

LH

RH

47...3 51...3 80...3 83...3 87...3

12VDC 12VDC 0-2VDC 0-2VDC 0-2VDC

47...3 53...3 90...3 93...3 97...3

12VDC 12VDC 0-2VDC 0-2VDC 0-2VDC

Forward Direction Console in Auto Mode Voltage Readings for 0 to Full Speed

Manual Operation Mode

LH

RH

51...3 81...3 83...3 87...3

12VDC 0-2VDC 0-2VDC 0-2VDC

53...3 91...3 93...3 97...3

12VDC 0-2VDC 0-2VDC 0-2VDC

Forward Direction Console in Manual Mode Voltage Readings for 0 to Full Speed

Override Mode

LH

RH

20576 (11/00)

51...3 52...3 83...3 87...3

12VDC 12VDC 2VDC 2VDC

53...3 54...3 93...3 97...3

12VDC 12VDC 2VDC 2VDC

Forward Direction Switches in Override Voltage Readings for Full Speed Only

17

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Wiring Diagram Operator Console

Figure 20

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18

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Wiring Diagram Main Junction

Figure 21

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19

Generation III Feeder Controls - P/N 49999-176

A

B

C

D

GND

+14V

AUTO OUT

MAN OUT

J1

11

8

5

2 OFF MANUAL

AUTO

10

12

7

9

4

6

1

3

20

J2

A B C D E

LH SENSOR +14V GND +8V SIGNAL GND

1/2 W

56 OHM

1/2 W

56 OHM

TB1 1

2

2

2

+14V

1

GND

20576 (11/00)

1

GND

4 4

3

4

VALVE -

3

3

VALVE + 0-2V

5

5

5

+8V

6

6

6

7

7

7

INPUT

PWB ASSY

OFFSET

8

8

8

GAIN SW

9

9

9

GAIN SW

10

10

10

CW

2

E

D

C

B

A

J3

PILE HEIGHT

GAIN

GND

SIGNAL

+8V

GND

+14V

RH SENSOR

HIGH

LOW

1 LOW

3 HIGH

Auto Mode 6.5V @ Low 1.5V @ High

Short Dist. 1.5V - Long Dist. 8.5V Depending on Material Height

Operation & Maintenance Manual

A Terex Company

Wiring Diagram

Control Box

Generation III Feeder Controls - P/N 49999-176 82 OHM

Operation & Maintenance Manual

A Terex Company

Troubleshooting Theory of Operation The Feed Conveyor System consists of a variable displacement hydrostatic pump that drives a hydrostatic motor. Output of the hydrostatic pump can be controlled by a variable electrical signal to the EDC (electrical displacement control) of the pump. A 0 to 2 volt dc signal changes the output speed from zero to maximum. The electrical signal to the EDC is affected by the following four (4) modes of operation:

Quick Troubleshooting Hints: The system consists of two (2) identical subsystems, Left and Right. This allows substitution of working components from one side with suspected nonworking components on the other side. If the problem follows the component, replace the faulty component. If the problem remains on the original side, further testing must be performed.

Manual Override: Signal from the proportional speed module mounted in main electrical junction box triggered by a relay which is energized by the Override switch(es). Fixed output is adjustable via Max and/or Limit pots on conveyor circuit card (Figure 14).

1) Sonic sensor (P/N 46061-100-20) affects automatic operation only.

These components are:

2) Sonic sensor cable (P/N 46061-100-23) affects automatic operation only. 3) Proportional sensor (P/N 46065-500-24) affects automatic operation only.

Manual: Signal from the Feeder Control box at either end of the screed. Speed adjustable via Pile Height knob (maximum speed is non-adjustable).

4) Feeder control box (P/N 46061-100-27) affects manual and automatic operation only. 5) Feeder control board (P/N 46061-100-22) located inside feeder control box affects automatic operation only.

Automatic : Signal from the Feeder Control box at either end of the screed. Speed variable via sensor signal which is limited by the pile height setting. This signal goes through the auto interlock relay contact on the conveyor circuit card in the main junction box on the tractor. This relay activates whenever the brakes are released and the control handle is pushed forward. Maximum output is adjustable via IMAX pot on feeder control board (Figure 15).

6) Proportional speed module (P/N 46065-50027) mounted in tractor main junction box affects override and automatic operation only. 7) Override/Stop toggle switches at console and at screed remotes affect operation in override, manual, and automatic modes.

Stop: Either Override/Stop switch in Stop position disconnects power from the Conveyor pump servo coils.

20576 (11/00)

21

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Left Conveyor Flow Charts Flow Chart #1

LH CONVEYOR WILL NOT OPERATE

FUNCTIONAL IN ANY MODE? OVERRIDE MANUAL OR AUTOMATIC?

MANUAL OVERRIDE ON No LH CONVEYOR PUMP CAUSE AUGER MOVEMENT?

No

No

Yes 0 VDC

Check VDC from #87 to #3

No

GO TO FLOW CHART LH #2

0.5 - 2.0 VDC

Replace EDC

>5 VDC

>5 VDC Does Remote Feed Override Work?

Refer to Hydraulic Troubleshooting

Check VDC at EDC plug

Repair or replace wiring harness(es) 0 VDC

Yes Does Operator Console Override Work? Yes

Does Manual at Feed Control Work?

No

Check VDC at wires #83 to #3

GO TO FLOW CHART LH #3

Faulty wiring or LH remote feed switch >5 VDC

0 VDC

No

Check VDC at wires #81 to #3

GO TO FLOW CHART LH #4

>5 VDC

Faulty wiring or LH conveyor override switch

Yes

Does Auto at Feed Control Work?

20576 (11/00)

No

GO TO FLOW CHART LH #5

22

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Left Conveyor Flow Charts Flow Chart #2 LH remote feed Override does not function

12 VDC from #52 to #3?

No

Faulty wiring or LH remote feed switch

No

Adjust/Replace adjustable speed module

No

Faulty wiring or LH conveyor override switch

No

Adjust/Replace adjustable speed module

Yes

2 VDC from #81 to #3 Yes

Functional

Flow Chart #3 LH conveyor override at console does not function

12 VDC from #52 to #3? Yes

2 VDC from #81 to #3 Yes

Functional

Flow Chart #4 LH manual feed control does not function

Check VDC from #81 to #3

0 - 8 VDC

Faulty wiring or LH conveyor override switch

0 - 8 VDC

Faulty wiring to main junction box on tractor

0 VDC Check VDC from TB1-10 to TB1-6 in feed control box 0 VDC Repair or replace feed control box

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23

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Left Conveyor Flow Charts Flow Chart #5 LH auto feed control does not function

Check indicator lamps (LED's) on feed control board Check VDC from pin B to Pin A in 10 pin connetctor at feed control box

No

+12 VOLTS light on? Yes

0 VDC

Faulty power wiring from main jct. box to feed control box

0 VDC

Replace auto-man switch or replace feed control box

12 VDC Check VDC from TB1-1 to TB1-6 in feed control box

>12 VDC Replace feeder control board in feed control box

No

+8 VOLTS light on?

6.5 to 1.5 VDC from MIN to MAX

Yes Check VDC from TB1-8 to TB1-3 on feed control board while moving pile height dial

No change in VDC

Replace pile height pot or feed control box

1.5 - 8.5 VDC w/Sonic (6"-42") 2 - 6 VDC w/wand (stop to stop) V OUT light on?

No change Check VDC from in VDC TB1-9 to TB1-6 in feed control box while moving sensor

No

Replace sensor

Yes Check VDC from TB1-4 to TB1-6 in feed control box

0 VDC

Faulty wiring inside feed control box

0 VDC

Faulty wiring from main jct. box to feed control box

>12 VDC Check VDC from #80 to #3 >12 VDC Check VDC from #81 to #3

0 VDC

Check VDC from #47 to #3

>12 VDC

Replace adjustable speed module

>12 VDC

Adjust/replace forward limit swich on control handle

0 VDC Check VDC from #34 to #3

>12 VDC

0 VDC

Faulty wiring on LH conveyor override switch 20576 (11/00)

24

Check and/or replace brake switch

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Left Conveyor Flow Charts Flow Chart #6 LH CONVEYOR WILL NOT STOP

Does disconnecting plug from pump control stop conveyor?

No

Refer to Hydraulic Troubleshooting

No

Replace LH remote feed switch

No

Replace LH conveyor switch

No

Replace MODE switch or feed control box

No

Replace PILE HEIGHT pot or feed control box

No

Replace PILE HEIGHT pot or feed control box

Yes

Does LH remote feed switch stop conveyor? Yes

Does LH conveyor switch at console stop conveyor? Yes

Does MODE switch at feed control box stop conveyor in STOP? Yes Does PILE HEIGHT dial control conveyor speed in MANUAL? Yes

Does PILE HEIGHT dial change material depths in AUTO? Yes

Does conveyor speed change relative to sensor position in AUTO?

No

Replace sensor

Yes Does conveyor stop when in AUTO with travel control handle in neutral?

Adjust or replace forward limit switch(es) on handle(s)

No

Yes Does conveyor stop when in AUTO with BRAKE engaged?

20576 (11/00)

No

Replace BRAKE switch

25

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Right Conveyor Flow Charts Flow Chart #1 RH CONVEYOR WILL NOT OPERATE

FUNCTIONAL IN ANY MODE? OVERRIDE MANUAL OR AUTOMATIC?

MANUAL OVERRIDE ON No RH CONVEYOR PUMP CAUSE AUGER MOVEMENT?

No

No

Yes 0 VDC

Check VDC from #97 to #3

No

GO TO FLOW CHART RH #2

0.5 - 2.0 VDC

Replace EDC

>5 VDC

>5 VDC Does Remote Feed Override Work?

Refer to Hydraulic Troubleshooting

Check VDC at EDC plug

Repair or replace wiring harness(es) 0 VDC

Yes Does Operator Console Override Work? Yes

Does Manual at Feed Control Work?

No

Check VDC at wires #93 to #3

GO TO FLOW CHART RH #3

Faulty wiring or RH remote feed switch >5 VDC

0 VDC

No

Check VDC at wires #91 to #3

GO TO FLOW CHART RH #4

>5 VDC

Faulty wiring or RH conveyor override switch

Yes

Does Auto at Feed Control Work?

20576 (11/00)

No

GO TO FLOW CHART RH #5

26

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Right Conveyor Flow Charts Flow Chart #2 RH remote feed override does not function

12 VDC from #54 to #3?

No

Faulty wiring or RH remote feed switch

No

Adjust/Replace adjustable speed module

No

Faulty wiring orRH conveyor override switch

No

Adjust/Replace adjustable speed module

Yes

2 VDC from #91 to #3 Yes

Functional

Flow Chart #3 RH conveyor override at console does not function

12 VDC from #54 to #3? Yes

2 VDC from #91 to #3 Yes

Functional

Flow Chart #4 RH manual feed control does not function

Check VDC from #91 to #3

0 - 8 VDC

Faulty wiring or RH conveyor override switch

0 - 8 VDC

Faulty wiring to main junction box on tractor

0 VDC Check VDC from TB1-10 to TB1-6 in feed control box 0 VDC Repair or replace feed control box

20576 (11/00)

27

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Right Conveyor Flow Charts Flow Chart #5 RH auto feed control does not function

Check indicator lamps (LED's) on feed control board Check VDC from pin B to Pin A in 10 pin connetctor at feed control box

No

+12 VOLTS light on? Yes

0 VDC

Faulty power wiring from main jct. box to feed control box

0 VDC

Replace auto-man switch or replace feed control box

12 VDC Check VDC from TB1-1 to TB1-6 in feed control box

>12 VDC Replace feeder control board in feed control box

No

+8 VOLTS light on?

6.5 to 1.5 VDC from MIN to MAX

Yes Check VDC from TB1-8 to TB1-3 on feed control board while moving pile height dial

No change in VDC

Replace pile height pot or feed control box

1.5 - 8.5 VDC w/Sonic (6"-42") 2 - 6 VDC w/wand (stop to stop) V OUT light on?

No change Check VDC from in VDC TB1-9 to TB1-6 in feed control box while moving sensor

No

Replace sensor

Yes Check VDC from TB1-4 to TB1-6 in feed control box

0 VDC

Faulty wiring inside feed control box

0 VDC

Faulty wiring from main jct. box to feed control box

>12 VDC Check VDC from #90 to #3 >12 VDC Check VDC from #91 to #3

0 VDC

Check VDC from #47 to #3

>12 VDC

Replace adjustable speed module

>12 VDC

Adjust/replace forward limit swich on control handle

0 VDC Check VDC from #34 to #3

>12 VDC

0 VDC

Faulty wiring on RH conveyor override switch 20576 (11/00)

28

Check and/or replace brake switch

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

Right Conveyor Flow Charts Flow Chart #6 RH CONVEYOR WILL NOT STOP

Does disconnecting plug from pump control stop conveyor?

No

Refer to Hydraulic Troubleshooting

No

Replace RH remote feed switch

No

Replace RH conveyor switch

No

Replace MODE switch or feed control box

No

Replace PILE HEIGHT pot or feed control box

No

Replace PILE HEIGHT pot or feed control box

Yes

Does RH remote feed switch stop conveyor? Yes

Does RH conveyor switch at console stop conveyor? Yes

Does MODE switch at feed control box stop conveyor in STOP? Yes Does PILE HEIGHT dial control conveyor speed in MANUAL? Yes

Does PILE HEIGHT dial change material depths in AUTO? Yes

Does conveyor speed change relative to sensor position in AUTO?

No

Replace sensor

Yes Does conveyor stop when in AUTO with travel control handle in neutral?

Adjust or replace forward limit switch(es) on handle(s)

No

Yes Does conveyor stop when in AUTO with BRAKE engaged?

20576 (11/00)

No

Replace BRAKE switch

29

Generation III Feeder Controls - P/N 49999-176

Operation & Maintenance Manual

A Terex Company

20576 (11/00)

30

Generation III Feeder Controls - P/N 49999-176

Sundstrand Automatic Grade and Slope Control

Operation & Maintenance Manual

Sundstrand Automatic Grade & Slope Control

A Terex Company

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Introduction

To the Owner & Operator: We have tried to provide information which will give you a clear understanding of equipment construction, function, capabilities and requirements. This information is based on the knowledge and experience of highly qualified people at our company and in our field organization. Proper use of this information will promote high efficiency, maximum service life and low maintenance costs. We strongly recommend that all persons directly involved with this equipment be familiar with this manual. The information contained in this manual should not be considered all-inclusive for every application. Questions about specific uses of this equipment should be directed to Cedarapids Inc. Anyone who uses this equipment for any purposes other than its intended use assumes the risk of any danger in doing so. Respectfully, Cedarapids Inc.

Important Notice! Federal, state and local safety regulations must be complied with to prevent possible danger to person(s) or property from accidents or harmful exposure. This equipment must be used in accordance with all operation and maintenance instructions. (1)

Read all warning, caution and instruction signs. Know what guards and protective devices are included and see that each is used. Additional guards and protective devices that may be required due to proximity to related equipment must be installed by the user (owner) before operating.

(2)

Never lubricate or adjust equipment when it is operating!

(3)

Securely lock out the involved power source before doing maintenance, cleaning, adjusting or repair. Secure the power source lockout to prevent start-up by other persons.

(4)

Wear a protective mask whenever harmful air pollution exists.

(5)

Use ear plugs whenever noise level is above established limits.

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Table of Contents

Description ........................................................................................................................ 1 Grade Control ................................................................................................................... 1 Grade Sensor Deadband ............................................................................................................................. 2 To Set Grade Sensor Deadband: ................................................................................................................. 2 Joint Matching Skate 46061-550-06........................................................................................................... 3 Ski 46061-550-07 ....................................................................................................................................... 3 Fixed String Line ........................................................................................................................................ 4

Slope Control..................................................................................................................... 5 Slope Deadband .......................................................................................................................................... 6 To Set Slope Sensor Deadband: .................................................................................................................. 6 Building Rideability - Sensor mounted forward......................................................................................... 7 To use the slope system: ............................................................................................................................. 7 Building Profile - Sensor mounted rearward .............................................................................................. 8 To use the slope system: ............................................................................................................................. 8

Troubleshooting Sundstrand Automatic Grade & Slope System ............................... 10 Amplifier Module ..................................................................................................................................... 10 Grade or Slope Not Working .................................................................................................................... 10 Slope Function Erratic .............................................................................................................................. 10 Automation Not Working Properly........................................................................................................... 10 Light Bulb Replacement ........................................................................................................................... 11 Remote Slope Set - No Display ................................................................................................................ 11 Remote Slope Set - Display Stays On Even When Unplugged ................................................................ 11 Remote Slope Set - Slope Appears to be Unstable or Oscillates .............................................................. 11 Slope Sensor ............................................................................................................................................. 11

Sundstrand Automatic Grade & Slope Control

i

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Table of Contents

Sundstrand Automatic Grade & Slope Control

ii

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Sundstrand Automatic Grade & Slope Control Description Automatic screed controls provide a means to enhance a paving operation by monitoring and controlling the screed position in relation to the tractor and the reference plane. This eliminates the need for a screed operator to manually introduce the changes that would be necessary for a uniformly smooth mat to be placed over irregular grades.

All of these reference in a plane parallel to the line of paving. Grade Control The grade controller consists of a housing containing a grade sensing module and an amplifying module which has indicator lights and a mode operation switch. A counter-balanced sensor arm can be attached to either side of the grade sensor. Depending on the application, a wand or a skate assembly is attached to the follower. (Figure 1) A grade sensor can control either the left or right tow point cylinder, depending on which side of the paver it is mounted. Dual grade sensors can also be used to control both left and right sides of the screed.

Automatic screed controls can enhance a good or proper paving operation by maintaining an established line of grade and/or percentage of slope. However, proper operation means controlling all of the factors that can adversely affect the screed. Refer to Quality Paving Guide Book. If these factors are not controlled by recommended operational techniques they can introduce a change in the screed’s position in relation to the established line of grade and/or percentage of slope quickly enough that the automation cannot correct for them. The automation cannot make up for improper operational techniques. Refer to Quality Paving Guide Book.

CABLE

Evaluation of specifications and grade conditions on a job is extremely important if the paver and automation are to be configured properly to produce the desired or required results. Failure to properly configure the screed and automation for each phase of the paving operation will result in producing a mat that is unsatisfactory or will not meet specifications. One configuration of the screed and automation will not produce superior results for all conditions and jobs.

SENSING ARM

SKATE RUNNER

STRINGLINE FOLLOWER

SKATE

The automation system consists of two basic sensory devices, the grade control and the slope control. Both systems operate independently of each other to control the screed’s angle-of-attack by moving the tow points up or down in relation to the reference plane of each. The reference plane for a grade sensory system can be one of three types, ski (mobile grade reference), joint matcher, or fixed (established) string line. The slope system uses an angular reference plane in relation to the horizon, which is perpendicular to the line of paving. Sundstrand Automatic Grade & Slope Control

GRADE CONTROLLER

Figure 1

The sensor arm can be mounted on either side of the sensor, depending on which side of the paver the sensor is to be mounted. The sensor arm has to be mounted so that it is trailing the sensor at 45° angle in relation to the flat on the sensor shaft, to work properly. (Figure 2)

1

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Sundstrand Automatic Grade & Slope Control If the sensing arm is mounted in a position other than 45°, the amount of rotation on the sensor module, in relation to the amount of deflection of the sensing arm, will not produce the correct amount of tow point cylinder movement. (Figure 3)

Grade Sensor Deadband

Mounting the sensor arm at any angle other than at 45°, changes the amount the sensor shaft is rotated for a given deviation. (Figure 4)

To Set Grade Sensor Deadband:

The deadband of the grade sensor refers to the amount the sensing arm can move without triggering a tow point cylinder response. A given amount is necessary to allow for normal machine vibration. 1) Assemble the grade sensor jack and mounting hardware. Place sensor on the jack and connect the electrical cable from the sensor to the tow point control connector. 2) When installing the sensor control arm, it is extremely important to install so it is trailing the sensor at 45° angle in relation the the flat on the sensor shaft. 3) Place the sensor Run/Standby switch in Standby mode. 4) Place the remote control mat thickness Manual/Setup/Auto switch in Setup mode. 5) Adjust the sensor jack height until both lights are out when the switch on the sensor is in Standby mode and the remote control material thickness switch is in the Setup mode. 6) The deadband is correct when a dime (.050 inch) can be passed under the follower without triggering a light, but a nickel (.080 inch) passed under the follower will trigger a light response. 7) If the deadband is not correct, remove the screw located on the face of the grade sensor. There is an adjustment located under the face screw. 8) Use the small screw driver provided. Clockwise rotation will increase the amount of deadband, while counterclockwise rotation will decrease the amount of deadband.

Flat on sensor shaft

Mount location 45°

Sensor Arm

Dead Band Set Point

45500- 036- 07

Complete Control 46061-550-15

Figure 2 With the sensor arm mounted at 45°, a 1/4 inch deviation will rotate the sensor shaft 3° 22' 52".

1/4" Sensor Arm Mounted Correctly

Figure 3 With the sensor arm mounted horizontally, the same 1/4 inch deviation only rotates the sentor shaft 2°27'46".

Sensor Arm Mounted Incorrectly

Figure 4

Sundstrand Automatic Grade & Slope Control

2

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Sundstrand Automatic Grade & Slope Control Joint Matching Skate 46061-550-06

Notice - Clockwise rotation of the grade sensor jack THICKENS the mat being placed. Counterclockwise rotation of the grade sensor jack THINS the mat being placed.

Matching the height of the mat being placed to an existing mat or curb requires the screed to be very responsive to any changes in the elevation of the existing mat or curb. This is an application where we are building "profile" or over-correcting the screed, forcing it to change depth in a very short distance. This mode is not necessarily good for rideability. 1) The grade sensor should be mounted 3/4 of the way back from the tow point, just ahead of the augers, and the sensor skate in as close to the joint as possible, taking into account the shape of the joint to be matched. If the joint being matched is distorted, it may be necessary to locate the sensor further from the joint. Keep in mind that the further the sensor is from the actual joint being matched, the less likely that an exact match will occur. 2) Place the sensor Run/Standby switch in Standby mode and the remote control mat thickness Manual/Setup/Auto switch in Setup mode.

Sensor Jack

Figure 6

Ski 46061-550-07 When using automation off a ski, corrections to deviations that occur at the sensor or the screed will require the paver to travel approximately 5 lengths of the tow arm before the correction is fully completed. Deviations that occur at the tow point due to the tractor traveling over irregular grades are corrected for immediately. In effect, the sensor is correcting for deviations at the tow point before they can affect the screed's angle of attack (position). In this application, we are building "rideability", or averaging all required changes in depth over a longer area.

(Centerline) CL

The grade sensor should be mounted 1/4 of the way back from the tow point.

Figure 5

3) Adjust the sensor jack assembly until the lights go out. 4) Place the sensor Run/Standby switch in Run mode and the remote control mat thickness Manual/Setup/Auto switch in Auto mode. 5) If mat depth needs correction, turn the grade sensor jack slowly in the correct direction until the mat being placed is the correct thickness. Sundstrand Automatic Grade & Slope Control

Sensor mounted forward

Figure 7 3

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Sundstrand Automatic Grade & Slope Control 1) Pave manually using the depth cranks until the correct depth is achieved. 2) Place the sensor Run/Standby switch in Standby mode and the remote control mat thickness Manual/Setup/Auto switch in Setup mode. 3) Adjust the sensor jack assembly until the lights go out. 4) Place the sensor Run/Standby switch in Run mode and the remote control mat thickness Manual/Setup/Auto switch in Auto mode. 5) If mat depth needs correction, turn the grade sensor jack slowly in the correct direction until the mat being placed is the correct thickness. Notice - Clockwise rotation of the grade sensor jack THICKENS the mat being placed. Counterclockwise rotation of the grade sensor jack THINS the mat being placed.

Sensor just ahead of auger

(Centerline) CL

Figure 9

1) Pave manually using the depth cranks until the correct depth is achieved. 2) Place the sensor Run/Standby switch in Standby mode and the remote control mat thickness Manual/Setup/Auto switch in Setup mode. 3) Adjust the sensor jack assembly until the lights go out. 4) Place the sensor Run/Standby switch in Run mode and the remote control mat thickness Manual/Setup/Auto switch in Auto mode. 5) If mat depth needs correction, turn the grade sensor jack slowly in the correct direction until the mat being placed is the correct thickness. Notice - Clockwise rotation of the grade sensor jack THICKENS the mat being placed. Counterclockwise rotation of the grade sensor jack THINS the mat being placed.

Figure 8

Fixed String Line When using automation off an established or fixed string line, it requires the screed to be responsive to any changes in elevation of the string line. This is an application where we are building profile, or overcorrecting the screed and forcing it to change depth in relation to the elevation of the string line. The grade sensor should be mounted 3/4 of the way back from the tow point, or just ahead of the augers. Sundstrand Automatic Grade & Slope Control

Figure 10 4

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Sundstrand Automatic Grade & Slope Control Slope Control

The position of the sensor, whether mounted on the forward cross beam or on the rearward cross beam, determines how fast the screed will react to a change of the null point at the sensor. By positioning the sensor, we can build profile or rideability. We need to evaluate job specifications and grade related conditions to determine the desired mounting position to produce the desired results.

The slope control system consists of a hand-held remote set unit, a slope sensor (pendulum) and an amplifier module which has indicator lights and a mode operation switch. On the CR351 and CR361 pavers the slope sensor and amplifier modules are incorporated into the same mount housing. (Figure 11) All other models have the slope sensor and amplifier modules mounted separately. (Figures 12 & 13) The slope control system can control the left or the right tow point cylinder and is capable of maintaining up to 10% positive or negative slope from each side of the paver. (Figure 14)

Slope Sensor, 400 and 500 Series Pavers

Figure 12

Slope System Components of the 300 Series Pavers

Slope Controller, 400 and 500 Series Pavers

Figure 11

Figure 13

Figure 14 Sundstrand Automatic Grade & Slope Control

5

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Sundstrand Automatic Grade & Slope Control Slope Deadband

3) Connect the slope amplifier to tow point control cable from the slope amplifier to either the left or right tow point connector.

The deadband on the slope system refers to the amount of angular change that can occur on the slope beam without triggering a tow point cylinder response. A given amount of deadband is necessary to allow for normal machine vibration.

Slope running on left tow point cylinder

Cable 46061-504-07

To Set Slope Sensor Deadband: 1) Connect the sensor harness from the slope amplifier to the slope sensor connection on the tractor bulkhead (slope sensor mounted forward). Or, from the slope amplifier to the slope sensor connection on the slope sensor (slope sensor mounted rearward). This step is not necessary on 300 series Grayhound pavers as the slope sensor and amplifier are in the same module.

Burner Control

Figure 17

Slope Sensor 46061-550-02-02

Slope running on right tow point cylinder Front Beam Mount

Rear Beam Mount Cable 46061-504-10

Cable 46061-504-07

Cable 46061504-09

Burner Control

OR Slope Amplifier Complete 46061-550-16

Figure 18

Figure 15

2) Connect the hand held remote control. +-

4) Place slope amplifier Run/Standby switch in Standby mode. 5) Place the remote control mat thickness Manual/Setup/Auto switch in Setup mode 6) Turn the slope set dial on the remote slope control until both lights on the slope amplifier go out. 7) Turn the remote slope control dial clockwise until a light just comes on, then turn counterclockwise until the light just goes out. Note the number readout on the LCD.

Hand Held Remote 46061-550-11

Module Card 46061-550-15-01 Figure 16 Sundstrand Automatic Grade & Slope Control

6

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Sundstrand Automatic Grade & Slope Control Building Rideability - Sensor mounted forward

8) Turn the remote slope control dial counterclockwise until a light just comes on, then turn clockwise until the light just goes out. Note the number readout on the LCD. 9) Subtract the smaller noted readout number from the larger. Example: 2.1 - 1.7 = 0.4 The deadband is set correctly if the differential from light to light is 0.2% slope. 10) If the deadband is not correct, remove the screw located on the face of the slope amplifier. There is an adjustment located under the face screw. 11)Use the small screw driver provided. Clockwise rotation will increase the amount of deadband, while counterclockwise rotation will decrease the amount of deadband.

When using a slope control system with the sensor mounted on the forward cross beam, corrections to deviations at the screed will require the paver to travel approximately 5 lengths of the tow arm before the correction is fully completed. Deviations that occur at the tow point, due to tractor traveling over irregular grades, are corrected for immediately. In effect, the sensor is correcting for deviations at the tow point before they can affect the screed’s angle of attack (position). In this application we are building “rideability”, or averaging all required changes in depth over a longer area.

Sensor forward

Figure 20

To use the slope system: 1) Connect system harnesses to control the desired left or right tow point cylinder as in Setting Deadband section. 2) Pave manually using the depth cranks until the desired slope is achieved on the mat being placed by checking with a carpenters level.

Dead-Band Set Point

Figure 19

Sundstrand Automatic Grade & Slope Control

7

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Sundstrand Automatic Grade & Slope Control Building Profile - Sensor mounted rearward

NOTICE - With a four foot level, 1/4” rise equals 1/2% slope and 1/2” rise equals 1% slope.

When using a slope control system with the sensor mounted on the rearward cross beam, requires the screed to be very responsive to any changes in the percentage of slope of the screed. This is an application where we are building “profile”, or overcorrecting the screed, forcing to change depth in a very short distance.

4 foot

1/4 inch = 1/2 % (0.5 %)

Figure 21

3) Place the Run/Standby switch on the slope amplifier to Standby and the remote mat thickness Manual/Setup/Auto switch in Setup. 4) Adjust slope hand held remote dial until the lights go out. 5) Remove the cover cap from the number set point potentiometer. 6) Adjust the number set point potentiometer until the LCD readout displays the correct percentage and fall of slope.

Sensor rearward

Figure 23 +/- Slope Indicator

+

LCD readout % of slope

-

To use the slope system: 1) Connect system harnesses to control the desired left or right tow point cylinder as in Setting Deadband section. 2) Pave manually using the depth cranks until the desired slope is achieved on the mat being placed by checking with a carpenters level.

Slope adjustment dial is used to change the actual percentage of slope being placed or is used to NULL slope (lights out) to the current slope of the screed.

Remote Unit requires 9 volt battery. (Be sure battery has adequate power.)

Display Calibration Knob (Changes display only. Does not change slope.)

NOTICE - With a four foot level, 1/4” rise equals 1/2% slope and 1/2” rise equals 1% slope.

Figure 22

7) Place the Run/Standby switch on the slope amplifier to Run and the remote mat thickness Manual/Setup/Auto switch in Auto.

4 foot

1/4 inch = 1/2 % (0.5 %)

Figure 24

Sundstrand Automatic Grade & Slope Control

8

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Sundstrand Automatic Grade & Slope Control 3) Place the Run/Standby switch on the slope amplifier to Standby and the remote mat thickness Manual/Setup/Auto switch in Setup. 4) Adjust slope hand held remote dial until the lights go out. 5) Remove the cover cap from the number set point potentiometer. 6) Adjust the number set point potentiometer until the LCD readout displays the correct percentage and fall of slope. +/- Slope Indicator

+

LCD readout % of slope

-

Slope adjustment dial is used to change the actual percentage of slope being placed or is used to NULL slope (lights out) to the current slope of the screed.

Remote Unit requires 9 volt battery. (Be sure battery has adequate power.)

Display Calibration Knob (Changes display only. Does not change slope.)

Figure 25

7) Place the Run/Standby switch on the slope amplifier to Run and the remote mat thickness Manual/Setup/Auto switch in Auto.

Sundstrand Automatic Grade & Slope Control

9

18121 (11/00)

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A Terex Company

Sundstrand Automatic Grade & Slope Control 7) Plug cable back into amplifier. 8) With the UP light on, check voltage on 155 to 3 (for LH tow point) or 165 to 3 (for RH tow point) for 12 VDC 9) With the DOWN light on, check voltage on 157 to 3 (for LH tow point) or 167 to 3 (for RH tow point) for 12 VDC. 10) If no voltage, take amplifier out of a unit known to be functioning properly and install it in system in question. Make sure slope/grade switch is set for unit to be used in. 11) If problem disappears, defective amplifier.

Troubleshooting Sundstrand Automatic Grade & Slope System WARNING - Hydraulic cylinders may activate unexpectedly during testing which could injure someone that is not prepared for such movement. The operator and maintenance personnel must be constantly aware of who is near the paver and what mechanisms may activate during testing. Ensure that personnel are clear of mechanisms that may activate during testing. Amplifier Module

Slope Function Erratic

The same amplifier module is used in both the grade and slope units. The only difference is the setting of the GRADE/SLOPE switch located on the back side of the amplifier module. If the unit is to be used as a grade control, set the Grade/Slope switch to GRADE. If unit is to be used as a slope control, set the Grade/Slope switch to SLOPE.

1) Check all connections for moisture. 2) If tow point cylinder “overshoots” during automatic operation, check for proper cylinder speed. Automation Not Working Properly 1) Perform checks on tractor base wiring and systems to ensure they function properly. 2) Inspect all cables and connections for damage. 3) Check the deadband setting on the amplifier. 4) Check the Grade/Slope switch on the back of the amplifier. It must be in GRADE if the amplifier is used in a grade senor and in SLOPE if the unit is used in the slope system. 5) If slope system is in question, refer to Remote Slope Set. 6) Check tow point solenoid valve DIN connectors for a light. Each solenoid valve has an LED that should light when power is applied to the solenoid. 7) Take the amplifier out of a unit that is known to be functioning properly and install it in the system in question. Make sure the slope/grade switch is set properly for the unit used. If problems disappear,defective amplifier.

Grade or Slope Not Working 1) Perform checks on tractor base wiring and systems to ensure they function properly. 2) Inspect cables and connections for damage. 3) If one side works and the other does not, swap sides with those components and recheck. If problem moves with the component, replace that component. 4) Set Manual/Setup/Auto switch to Manual. Do the tow point cylinders go up and down when selected? If they do, proceed with the next step. If they do not, troubleshoot tractor wiring and/or systems. 5) Set Manual/Setup/Auto switch to Setup, set Standby/Run switch to Run. 6) Disconnect large cable from amplifier. Check pins A to B on cable for voltage. It should be 11 VDC or more. If low or no voltage, troubleshoot tractor wiring and/or systems. Sundstrand Automatic Grade & Slope Control

10

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Sundstrand Automatic Grade & Slope Control Light Bulb Replacement

Slope Sensor

Unscrew the lens cover from the bulb. Slide a piece of 5/16” inside diameter rubber hose over the bulb. Press down and turn bulb counterclockwise. The bulb can be purchased at most local vendors as #161 (12 VDC) bulb.

Disconnect cable and check ohms between pins.

Remote Slope Set - No Display

No cross continuity.

A to B: 10 ohms C to D: 300 ohms E to F: 300 ohms

1) Check battery in backside of remote slope hand held unit and replace if necessary. A dead battery will cause the LCD to blank out. 2) Check harnesses and connections for damage. 3) Check pins A to C on the slope amplifier (connection point that remote plugs into). Voltage should be at least 2.1 VDC. If voltage is OK, defective remote slope set unit. 4) If no or low voltage, unplug the harness coming from tow point. Check pins A to B on the socket end. Voltage should be 11 VDC or more. 5) If voltage, defective amplifier. 6) If no or low voltage, check tractor base wiring or systems. Remote Slope Set - Display Stays On Even When Unplugged Replace remote slope set unit. Remote Slope Set - Slope Appears to be Unstable or Oscillates 1) Check deadband setting on amplifier. 2) If deadband is OK, unplug remote slope set unit and check pins B to D for 1500 ohms. 3) If a reading shows 500 ohms, a capacitor is shorted. Replace unit. 4) Check pins A to C for 2500 ohms, then check for continuity between pins A to B and pins B to C while rotating dial. Reading should vary as dial is turned. If not, replace unit. Sundstrand Automatic Grade & Slope Control

11

18121 (11/00)

Operation & Maintenance Manual

A Terex Company

Sundstrand Automatic Grade & Slope Control

Sundstrand Automatic Grade & Slope Control

12

18121 (11/00)

System Four Grade & Slope Automation

Operation & Maintenance Instructions

System Four Grade and Slope Automation

A Terex Company

21048 (12/95)

Part # 49999-188

Operation & Maintenance Manual

A Terex Company

Introduction

To the Owner & Operator: We have tried to provide information which will give you a clear understanding of equipment construction, function, capabilities and requirements. This information is based on the knowledge and experience of highly qualified people at our company and in our field organization. Proper use of this information will promote high efficiency, maximum service life and low maintenance costs. We strongly recommend that all persons directly involved with this equipment be familiar with this manual. The information contained in this manual should not be considered all-inclusive for every application. Questions about specific uses of this equipment should be directed to Cedarapids Inc. Anyone who uses this equipment for any purposes other than its intended use assumes the risk of any danger in doing so. Respectfully, Cedarapids Inc.

Important Notice! Federal, state and local safety regulations must be complied with to prevent possible danger to person(s) or property from accidents or harmful exposure. This equipment must be used in accordance with all operation and maintenance instructions. (1)

Read all warning, caution and instruction signs. Know what guards and protective devices are included and see that each is used. Additional guards and protective devices that may be required due to proximity to related equipment must be installed by the user (owner) before operating.

(2)

Never lubricate or adjust equipment when it is operating!

(3)

Securely lock out the involved power source before doing maintenance, cleaning, adjusting or repair. Secure the power source lockout to prevent start-up by other persons.

(4)

Wear a protective mask whenever harmful air pollution exists.

(5)

Use ear plugs whenever noise level is above established limits.

16885 (7/91)

Operation & Maintenance Manual

A Terex Company

Table of Contents

Introduction ..................................................................................................................................................................1 About This Manual .....................................................................................................................................................1 About Cedarapids Inc. ................................................................................................................................................1 Safety .............................................................................................................................................................................2 Safety Rules ................................................................................................................................................................2 Personal Safety Rules .................................................................................................................................................2 Hazard Seriousness Level ...........................................................................................................................................2 Instructional and Informational Levels .......................................................................................................................2 System Overview ..........................................................................................................................................................4 Control Box ................................................................................................................................................................4 Sonic Tracker II ..........................................................................................................................................................4 Slope Sensor ...............................................................................................................................................................5 Junction Box ...............................................................................................................................................................5 Carrying Case .............................................................................................................................................................5 System Four Signal Routing .......................................................................................................................................6 Non-Contacting Systems ............................................................................................................................................6 Sonic Tracker II: How It Works ..................................................................................................................................6 The Working Window .................................................................................................................................................7 Slope Sensor: How It Works .......................................................................................................................................8 Slope Sensor Correction Zones ..................................................................................................................................8 Function .........................................................................................................................................................................9 Control Box ................................................................................................................................................................9 Control Box Front Panel Switches and Controls ........................................................................................................9 1) Grade Correction Display ..................................................................................................................................9 2) Auto/Manual/Survey (Cal) Switch ....................................................................................................................10 3) Jog Switch ......................................................................................................................................................... 11 4) Elevation: Power/Off/Slope: Power Switch ...................................................................................................... 11 5) Grade Adjustment Knob .................................................................................................................................... 11 6) LCD Digital/Symbol Display ............................................................................................................................ 11 Lower Control Box Components .............................................................................................................................. 12 1) Serial Number Plate ......................................................................................................................................... 12 2) 11 Pin Cable Connector ................................................................................................................................... 12 3) Audible Beeper ..................................................................................................................................................12 4) Mounting Knob .................................................................................................................................................12 Control Box Memory ................................................................................................................................................ 12 Entering Survey/Control Mode ................................................................................................................................. 12 Calibrating the Tracker or Slope Sensor (changing numbers only) ..........................................................................13 Accessing System Four Performance Settings ......................................................................................................... 13 1) Blank Screen ..................................................................................................................................................... 14 2) Gain (Elevation) ............................................................................................................................................... 14 3) Gain (Slope Control) ......................................................................................................................................... 14 4) Slope Resolution ............................................................................................................................................... 15 21048 (12/95)

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5) Beeper ............................................................................................................................................................... 15 6) Hour Meter .......................................................................................................................................................15 7) Deadband .......................................................................................................................................................... 16 8) Valve Offset .......................................................................................................................................................16 9) Unit ...................................................................................................................................................................17 Sonic Tracker II ........................................................................................................................................................17 Sonic Tracker II Front Panel .....................................................................................................................................18 1) Grade Correction Display ................................................................................................................................18 2) Sonic Tracker II Bail LED ................................................................................................................................18 Sonic Tracker II Rear ................................................................................................................................................ 18 1) Mounting Access ............................................................................................................................................... 18 2) Serial Number Plate ......................................................................................................................................... 19 3) 11 Pin Connector .............................................................................................................................................. 19 4) Temperature Sensor .......................................................................................................................................... 19 Sonic Tracker II Bail .................................................................................................................................................19 Sonic Tracker II Bail Installation .............................................................................................................................. 19 Sonic Tracker II Components ................................................................................................................................... 20 Sonic Tracker II Transducer Replacement ................................................................................................................ 20 Slope Sensor .............................................................................................................................................................20 Junction Box .............................................................................................................................................................20 Power & Interlock (Screed Remote Controls) .......................................................................................................... 21 Burner Control Console Components ....................................................................................................................... 22 Tow Point Valves .......................................................................................................................................................22 Right Tow Point Valves .......................................................................................................................................... 22 Left Tow Point Valves ............................................................................................................................................. 22 Solenoid Valve Din Connectors ............................................................................................................................. 23 Getting Started ........................................................................................................................................................... 24 Getting an On Grade Bar: (NULLING) ....................................................................................................................24 Sonic Tracker II Control ........................................................................................................................................ 25 Slope Control ......................................................................................................................................................... 25 Setting Control Box Display (Changing Numbers ONLY): ................................................................................... 26 Sonic Tracker II Control ........................................................................................................................................ 26 Slope Sensor Calibration ......................................................................................................................................26 Getting Started Paving .............................................................................................................................................. 26 Transverse Joints ................................................................................................................................................... 28 Joint Preparation ................................................................................................................................................ 28 Nulling the Screed .................................................................................................................................................28 Line of Pull ............................................................................................................................................................ 29 Building Rideability or Profile ................................................................................................................................. 29 Evaluation of Jobs .................................................................................................................................................29 Building Profile ..................................................................................................................................................... 29 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Table of Contents

Sensor Positioning .................................................................................................................................................30 Effective Length of Tow Arm ................................................................................................................................. 30 Control References ................................................................................................................................................... 30 Grade Control (Joint Matching) ........................................................................................................................... 30 Grade Control (Ski) ............................................................................................................................................... 31 Averaging Ski .................................................................................................................................................... 31 Over the Screed Ski ...........................................................................................................................................31 Existing Surface .................................................................................................................................................... 32 Curb or Gutter ...................................................................................................................................................... 32 Surface Stringline ..................................................................................................................................................32 Slope Table ............................................................................................................................................................... 33 Maintenance and Parts .............................................................................................................................................. 34 Preventative Maintenance & Daily Care .................................................................................................................. 34 Illustrated Parts Guide .............................................................................................................................................. 34 Illustrated Parts Guide .............................................................................................................................................. 35 Illustrated Cable Guide ............................................................................................................................................. 36 System Four Cable Numbers ................................................................................................................................. 37 Transducer Replacement Procedure .........................................................................................................................37 Sonic Tracker II Transducer Replacement ............................................................................................................ 37 Connector and Wiring Diagram ........................................................................................................................ 38 - 39 Troubleshooting .......................................................................................................................................................... 40 System Checkout Grade ...........................................................................................................................................40 System Checkout Slope ............................................................................................................................................41 Operating Checkout Grade ....................................................................................................................................... 42 Operating Checkout Slope ........................................................................................................................................ 44 System Performance Operational Check .................................................................................................................. 45 Symptom Quick Reference ....................................................................................................................................... 47 Troubleshooting Procedures .....................................................................................................................................47 LH Electrical Automatic Screed Control .................................................................................................................. 48 Tow Point Cylinder Does Not Raise or Lower in Manual ..................................................................................... 48 Topcon Control Does not Raise or Lower Tow Point in Manual or Auto ............................................................. 48 RH Electrical Automatic Screed Control .................................................................................................................. 49 Tow Point Cylinder Does Not Raise or Lower in Manual ..................................................................................... 49 Topcon Control Does not Raise or Lower Tow Point in Manual or Auto ............................................................. 50 Tow Point Hydraulic .................................................................................................................................................50 Auxiliary System .................................................................................................................................................... 50 Tow Point Will Not Increase .................................................................................................................................. 50 Tow Point Will Not Decrease ................................................................................................................................. 51 Tow Point Cylinder Drifts Up or Down ................................................................................................................ 51 Tow Point Cylinder Timing ......................................................................................................................................51 Checking Cylinder Timing .....................................................................................................................................51 Tow Point Timing Adjustment ................................................................................................................................52 21048 (12/95)

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System Four Grade and Slope Automation

Introduction About This Manual We have tried to provide information which will give you a clear understanding of equipment construction, function capabilities and requirements. This information is based on the knowledge and experience of highly qualified people at our company and in our field organization. Proper use of this information will promote high efficiency, maximum service life and low maintenance. We strongly recommend that all persons directly involved with this equipment be familiar with this manual whether or not you have experience with previous generations of machines. Experience has shown that it is to your advantage to have a copy of this manual on site where the operators can consult it as needed and have a copy on file in your office so supervisors can conveniently refer to it. Danger! This manual contains vital information essential to proper and safe operation of this equipment. Carefully read the entire manual before attempting to operate this equipment. Failure to follow instructions and warnings contained in this manual can cause severe personal injury or death or substantial property damage. Additional copies can be ordered through your local Cedarapids Distributor Representative. On going improvement of product design may result in future changes to some parts. When ordering replacement parts, please be exact as possible in describing the part. Use part numbers, model number and serial number to communicate with your local Cedarapids Distributor Representative. When you have a question about your machine or operation manual, please contact your local Cedarapids Distributor Representative. About Cedarapids Inc. Cedarapids is proud to manufacture this machine for your use and profit. We also take pride in the quality of our service and replacement parts. Cedarapids Inc., located in Cedar Rapids, Iowa, USA, has been manufacturing heavy equipment for the construction industry since 1923. Our friendly, helpful people are ready and able to serve your needs. If you have a question or concern please feel free to give us a call at (319) 363-3511 Monday - Friday 7:30 am to 4:30 PM Central Time. If you have a problem and need assistance during after hours, call our emergency service number at (319) 398- 9114. An operator will get your name and number so a service representative can return your call (usually with in 30 minutes). If your concern can not be resolved at that time a representative from engineering will be contacted. We are looking forward to serving you.

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System Four Grade and Slope Automation Safety

• This equipment must be used in accordance with all operation and maintenance instructions.

Safety Rules When operating the equipment, always follow the safety rules. Cedarapids makes no guarantee either expressed or implied that the equipment meets all local or federal safety regulations. It is the responsibility of the individual user to verify that all safety regulations are complied with before starting the machine.

• We strongly recommend that all persons involved with this equipment be familiar with this manual and all related engine manuals. • Read all Danger, Warning, Caution and instruction decals. • Know what guards and protective devices are included and see that each is used.

Personal Safety Rules Cedarapids equipment is designed with the safety of all personnel in mind. Do not attempt to change, modify, or eliminate the accident prevention devices installed at the factory. Make sure all personnel who regularly work or who might do work in the area of the equipment are familiar with the safety precautions. Owners and operators are responsible for safety information and following safe practices.

Hazard Seriousness Level Signal words (Danger!, Warning! and Caution!) are used to identify levels of hazard seriousness in this manual and on decals located on the equipment.

Guards, covers, and shields are installed around moving parts at the factory whenever necessary to prevent accidental injury to operators and others working on or near the equipment. Do not remove them. In some cases it is the customer’s responsibility to properly guard the machine before operation.

Warning! Hazards or unsafe practices which COULD result in severe personal injury or death.

Definitions for identifying hazard levels are provided below with their respective signal words. Danger! Immediate hazards which WILL result in severe personal injury or death.

Caution! Hazards or unsafe practices which COULD result in minor personal injury. Instructional and Informational Levels Signal words (Notice and Important) are used to identify instructional procedures and informational suggestions or directions for Cedarapids equipment operation and maintenance

Danger! This manual contains important information regarding the operation of your machine. Carefully read the entire manual before attempting to operate. Failure to read this manual and follow the instructions and warnings in it can cause severe personal injury, death or substantial property damage.

Definitions for identifying instructional or informational levels are provided below. Notice Notice: Failure to follow proper instructional procedures could lead to serious and/or expensive damage to the equipment.

• Only qualified and trained persons should operate, repair or maintain this equipment. • Keep this manual for future reference. • Federal, state and local safety regulations must be complied with to prevent possible danger to person(s) or property from accidents or harmful exposure.

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System Four Grade and Slope Automation Important Important: Informational suggestions or directions regarding operational and maintenance of equipment.

• Mount and dismount the machine using only the steps, handrails and walkways. • Do not mount or dismount the machine when it is moving.

Danger! Failure to avoid the following hazards will result in severe personal injury or death.

• Keep all personnel clear of machine when operating. Caution! Failure to heed the following could result in personal injury.

• Never attempt to install or remove any part or assembly when the paver is running.

• Wear protective mask when harmful air pollution exists.

• Do not allow personnel to walk between the machine and truck.

• Wear safety goggles, gloves and long-sleeve shirts when in close proximity to hot asphalt materials.

• Do not refule the machine with the engine running. All sparks and open flames must be kept to a minimum of 50 feet away from the machine while refueling.

• Wear ear plugs if needed. • To prevent fire hazards, keep the engine area free of oil, fuel and trash buildup.

Warning! Failure to take action to resolve these hazards or unsafe conditions could result in severe personal injury or death. • Wear clothing that fits snug to prevent getting caught in moving parts. Loose-fitting clothing should never be worn.

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System Four Grade and Slope Automation System Overview

All of the controls for the System Four are on the front panel of the Control Box. The Control Box connects to the Junction Box on the respective side with one cable. It attaches easily with one mounting clamp, and at the end of the day can be quickly removed for storage.

System Four is a complete, non-contacting control system which combines both elevation control and slope control into a simple, easy to use package. The system includes two Control Boxes, two Sonic Tracker II’s and a single Slope Sensor. The Control Box on the right side of the machine controls the right side for either elevation or slope. Likewise, the left Control Box controls the left side for either elevation or slope.

Sonic Tracker II The Sonic Tracker II is an elevation control sensor. It sends out pulses of high frequency sound and measures the time it takes for the echoes reflected from physical objects to return. Sonic Tracker II then sends that information to the Control Box. The Control Box then evaluates the information and raises or lowers the towpoint cylinder to maintain proper mat thickness.

The primary function of the System Four is to provide screed control so that the paving material is placed into position at the correct elevation and slope. Control Box The Control Box is the operator’s interface to System Four. The Control Box receives signals from the sensors, (Sonic Tracker II, Laser Trackers and/or Slope Sensor), and uses these signals to determine if grade or slope correction is necessary. If a change in grade or slope is required, the Control Box sends a signal to the valve controlling the tow point cylinder on the appropriate side of the machine to raise or lower, thus maintaining correct mat thickness.

Sonic Tracker II attaches to the system through one quick connect cable and attaches to the machine with a single bolt. At the end of the day, Sonic Tracker II should be removed for proper storage in the carrying case.

AUTO

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System Four Grade and Slope Automation Slope Sensor The Slope Sensor is a precision electronic sensor which functions much like a precision carpenters level. The Slope Sensor reads the inclination (tilt) of the screed and sends the signal to the Control Box.

The Junction Box allows for quick and easy attachment and removal of the system cables, and once installed on the paving machine it is not removed. Carrying Case A Carrying Case is provided with each System Four. The Carrying Case is lined and includes pre-cut sections for each Sonic Tracker II and Control Box. A plastic bucket is also provided for storing coil cords and cables.

The Slope Sensor is a sealed unit and contains no adjustments. It is the only component of System Four which may be selected to control either side of the paver. It is connected to both Junction Boxes by two cables, and is not removed from the paver once installed.

ON

C OP

T

Junction Box The primary function of the Junction Box is to route power and ground from the paving machine to the Control Box, and to route correction signals from the Sonic Tracker II or Slope Sensor to the Control Box. It also routes valve signals from the Control Box to the paving machine valves.

At the end of each job or at the end of the day, always wipe down each of the components and place them and the coil cords in the appropriate sections for storage. This will ensure the continued integrity of these components and will protect them from vandalism or theft. Notice: Keep the Carrying Case dry and store in a dry location. Never let the Carrying Case become wet. If the case does become wet, remove the components and air until dry.

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System Four Grade and Slope Automation System Four Signal Routing

LEFT SOLENOID VALVE & TOW POINT CYL.

RIGHT SOLENOID VALVE & TOW POINT CYL.

D

D C

SONIC GRADE SENSOR

JUNCTION BOX B

A

SLOPE SENSOR

CONTROL BOX

JUNCTION BOX

C

SONIC GRADE SENSOR

B

CONTROL BOX

A

(A) The Sonic Tracker II measures the distance between it and the reference plane and sends the information to the Control Box.

principles of the Sonic (Sonic Tracker II) and the Gravitational (Slope Sensor) devices supplied with System Four.

(B) The Slope Sensor measures angle of the slope beam and sends the information to the Control Box.

Sonic Tracker II: How It Works The Sonic Tracker II measures distances to a physical reference (Control Reference) using sound pulses, much like a SONAR.

(C) The Control Box determines if corrections are required and sends correction signals to the pavers hydraulic valve.

A Transducer, located in the bottom of the Sonic Tracker II generates sound pulses like a speaker, and listens for returned echoes like a microphone. When the Transducer generates a sound pulse, it also starts a counter that is a lot like a stopwatch.

(D) The pavers hydraulic valve responds by moving the tow point cylinder to make the correction. Non-Contacting Systems Non-Contacting Grade control or Paving control systems operate from Sonic, Laser or Gravitational sensors that do not require physical contact with a Control Reference to maintain a desired Elevation or Slope. The following sections will explain the

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System Four Grade and Slope Automation The Working Window Before paving is started, the operator will use the Control Box to set (or Calibrate) a control region or zone around the Control Reference (see Sonic Tracker II Calibration). This process is called “Nulling”.

The pulse travels away from the Sonic Tracker II at the speed of sound, gradually increasing in diameter.

Sound Pulse

When the sound pulse strikes an object (Control Reference), a portion of the sound pulse is reflected back up toward the Transducer. The size of the cone determines what the Sonic Tracker II can “see”. Objects within the cone reflect sound back (an echo). Objects outside of the cone do not reflect back sound. When the Transducer “hears” the returning sound pulse (echo), the Sonic Tracker II stops the counter. Using the elapsed time measured by the counter and knowing the speed of sound, the Sonic Tracker II calculates the exact distance to the object (Control Reference). It repeats this procedure 40 times per second.

ADJUSTABLE 14" TO 55" (35.5 TO 140 cm)

2.4"(6 cm) 2.4"(6 cm)

Solid Up Arrow Flashing Up Arrow On Grade Flashing Down Arrow Solid Down Arrow

AT 24" THE 24" SOUND PULSE WILL BE APPROXIMATELY 6" IN DIAMETER

No Correction Made

Coarse Correction (Automatic)

Fine Correction (Automatic)

The Working Window is a zone 2.4" above and 2.4" below the On Grade distance. When the distance measured by Sonic Tracker II to the Control Reference is within the Working Window, automatic control of the screed can occur. If the distance measured is outside of the control window, control is switched to manual and no corrections are sent to the control valve unless the measured distance is returned to within the Working Window. This prevents the system from “diving” should the Sonic Tracker II be moved off of a Control Reference like ski, stringline, or curb. Transducer generates a sound pulse and starts timer.

Sound pulse strikes control reference

Echo returns and stops timer

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System Four Grade and Slope Automation Under automatic control, the Control Box tries to keep the Control Reference at a constant distance from the Sonic Tracker II (On Grade). If the Sonic Tracker II measures the distance to the Control Reference and the Control Box finds its not at the desired distance (On Grade), the Control Box determines which part of the Working Window (Fine or Course Correction above or below On Grade) the Control Reference is residing in. Once this is determined, the Control Box displays the appropriate correction symbol on its LED Display as well as on the Sonic Tracker II LED Display, and sends correction signals to the paver valve to adjust the screed to bring the screed back to On Grade. COARSE CORRECTION UP

SOLID ARROW UP

FINE CORRECTION UP

FLASHING UP ARROW

ON GRADE

ON GRADE

FINE CORRECTION DOWN

FLASHING DOWN ARROW

_

_

+

SystemFour

SystemFour

SystemFour

+

+

%

%

%

Once the desired Slope has been set at the Control Box, the Slope Sensor measurements will be indicated on the Control Box LCD and LED Displays. When the paver is at the correct slope (On Grade), the Control Box will display the On Grade Symbol.

COARSE CORRECTION UP

Slope Sensor Correction Zones The Control Box receives signals from the Slope Sensor and sets up Correction Zones regions around the On Grade Zone. These Correction Zones are divided into two sections. Just above and just below On Grade to ± .05% is the Fine Correction Zone. Any slope measured beyond the Fine Correction Zones is in the Course Correction Zone. When a slope that is more than ± 2.0% beyond On Grade is encountered, a Grade Adjustment Arrow around the Grade Adjustment Knob will illuminate.

SOLID ARROW DOWN

If the Control Reference is measured to be outside of the Working Window (above, or below 2.4" of On Grade), the LED arrows on Sonic Tracker II will flash once every two seconds, and one of the Grade Correction Arrows around the Grade Correction Knob on the Control Box will flash indicating which way to turn the knob to bring the Working Window back around the Control Reference. The System will also be placed under manual control.

Each of these Correction Zones also have there own symbols. While displaying the desired control slope of the paver on the Control Box LCD Display, symbols will also appear on the Control Box LED’s so the operator knows, at any time, the correction needed for the paver to reach On Grade.

Slope Sensor: How It Works The Slope Sensor has a precision electronic device much like a carpenter’s level inside the slope sensor that constantly measures the slope that the paver is operating on. Using the Control Box to set (Calibrate) the Slope Sensor (see Slope Sensor Calibration), the operator can maintain a desired left hand or right hand slope from +20% to -20%.

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_

+

8

COARSE CORRECTION UP

FINE CORRECTION UP

SOLID ARROW UP

FLASHING UP ARROW

ON GRADE

ON GRADE

FINE CORRECTION DOWN

COARSE CORRECTION UP

FLASHING DOWN ARROW

SOLID ARROW DOWN

Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation Function

1) Grade Correction Display LED’s

This chapter reviews the System Four components and explains the function of each.

2) Auto/Manual/Survey (Cal) Switch 3) Jog Switch

Notice: When operating in rainy weather or in wet conditions, the Control Box, Sonic Tracker II, and cables must be thoroughly dried BEFORE placing them in the Carrying Case at the end of the day.

4) Elevation: Power Off Slope: Power 5) Grade Adjustment Knob 6) LCD Display All features of the System Four can be accessed using the switches and displays located on the front panel of the Control Box.

Any moisture left on the Control Box, Sonic Tracker II, and/or cables when put in the Carrying Case will cause condensation on the inside of the components which may severely affect accurate operation during the next paving operation.

The function of each is as follows: 1) Grade Correction Display The Grade Correction Display cues you when grade is too high, on grade or too low.

Control Box The Control Box is the main operator control interface for the System Four. It contains LED’s (Light Emitting Diodes) as well as an LCD (Liquid Crystal Display) to inform the operator of the systems performance. The Control Box’s LED’s duplicate the symbols being displayed on the Sonic Tracker II’s LED display.

• Control Box LED’s indicate the correction required to return to grade. Too High (lower tow point to reach grade) Flashes when within .6" 1.5 cm, of On Grade Solid when greater than .6" (1.5cm) but less than 2.4" (6 cm) of On Grade

The Control Box is also the “brains” of the System Four. It receives information from the sensors, processes the information, and sends out correction signals to the paver’s tow arm valves.

Off when beyond 2.4" (6 cm) of On Grade

Control Box Front Panel Switches and Controls

On Grade At correct grade.

1 SystemFour

(the depth of On Grade depends on the amount of deadband calibrated)

6

Auto

2 SurveyCal

TOPCON

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System Four Grade and Slope Automation Too Low (Raise tow point to reach grade)

this chapter). Holding the switch again for less that 2 (two) seconds will set the Control Box to the Control Mode (see “Survey/Control Function” later in this chapter).

Flashes when within .6" (1.5 cm) of On Grade Solid when greater than .6" (1.5cm) but less than 2.4" (6 cm) of On Grade

B) After the Control Box has been powered On, continuously holding this switch down while turning the Grade Adjustment Knob will set the Control Box LCD to a new numerical value. (See “Calibrating the Tracker or Slope Sensor” later in this chapter).

Off when beyond 2.4" (6 cm) of On Grade Survey Mode (Flashing) Indicates that the system is no longer in Control Mode and that the LCD Display is now showing the actual grade or slope of the screed.

C) Powering On the Control Box while holding the switch down continuously will allow selection of system Performance Settings. The Grade Correction Arrows will flash and the LCD will be blank. Turn the Grade Adjustment Control Knob (while continuing to hold down the Auto/Manual/Survey (Cal) Switch) to the right 1 (one) click at a time. The Calibration Modes will appear in the following order:

2) Auto/Manual/Survey (Cal) Switch The Auto/Manual/ Survey (Cal) Switch is used to AUTO select Manual or M A Automatic control and to N calibrate the System Four.

1) Blank (Exit) 2) Gain (Elevation) 3) Gain (Slope)

SURVEY (CAL)

4) Unit (Sets unit of measure: Ft/In/cm) 5) Slope Resolution (Sets to: . 1 or to: .01)

• Up position sets the system to the Automatic Mode. This is the normal operating mode. Paver tow arms are automatically adjusted up or down to maintain proper grade.

6) Beeper (Sets audible beep to On or Off) 7) Hour Meter (Total hours the system has been On/Total hours system has been in the Auto Mode)

• Center position sets the system to the Manual Mode. In this mode System Four will give readings, but the pavers tow arms will not be adjusted.

8) Deadband (Sets On Grade Deadband) 9) Valve Offset (See “Accessing System Four Performance Settings” later in this chapter).

• Down position controls three separate functions: A) After the Control Box has been powered on, holding this switch down less than 2 (two) seconds will set the Control Box in the Survey Mode (see “Survey/Control Function” later in 21048 (12/95)

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System Four Grade and Slope Automation 3) Jog Switch

Grade Adjustment Direction Arrows These red arrows light up around the Grade Adjustment Knob to indicate the direction the knob should be rotated to reach On Grade.

This switch is used to manually move the tow point up or down. The Jog Switch is always active when the Control Box is turned on. Up position causes the tow arm cylinder to raise. Down position causes the tow arm cylinder to lower.

1) Rotate the knob to the right to reach grade.

4) Elevation: Power/Off/Slope: Power Switch This switch sets the control for either Elevation or Cross Slope. It is also the power switch for the system.

2) Rotate the knob to the left to reach grade. 6) LCD Digital/Symbol Display This display allows the operator to view a numerical representation of the grade or slope the System Four is currently maintaining. When setting System Four performance settings, their individual symbols will be displayed (See “Accessing System Four Performance Settings” later in this chapter).

Up position turns power On and selects Elevation Control. Middle position turns power Off. Down position turns power on and selects cross Slope Control.

• Graphic symbols indicate the type of control that has been selected:

5) Grade Adjustment Knob This knob is used to make measured adjustments to the cross slope or elevation settings.

_

This knob is also used to access Calibration and System Performance Settings when used in conjunction with the Auto/Man/Survey (Cal) Switch. (See “Calibrating the Tracker or Slope Sensor” or “Accessing System Four Performance Settings” later in this chapter).

+

Cross Slope Control Slope down to the right

Cross Slope Control Slope down to the left (+)

Sonic Tracker II Control

Laser Tracker Control

• Adjusts the grade height for the Sonic Tracker II when elevation control is selected. • Adjusts the percentage slope when cross slope control is selected.

• When Cross Slope Control is selected, the numbers on the display represent percentage of slope. 21048 (12/95)

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System Four Grade and Slope Automation • When Elevation Control is selected, the numbers on the display represent elevation measurements in either feet, inches, or centimeters.

attached to the Control Box and is long enough to allow the Mounting Knob to be loosened without being removed from the stud when mounting the Control Box. Control Box Memory The Control Box automatically stores all operating information when it is turned Off.

Auto Indicator

AUTO

This indicator illuminates when the system is switched to Automatic.

NOTICE: If power is interrupted to the Control Box within 2 (two) seconds after making an adjustment, the new setting will not have had time to be stored and the settings will revert to the previous (or original) setting.

Lower Control Box Components

1

Entering Survey/Control Mode The Survey Mode allows the operator to view the actual elevation or slope of the screed. In this mode, the LCD Display reading will change as the screed is raised or lowered or tilted. This feature is useful in setting up the machine or pre-surveying the job.

4

NOTICE: The screed cannot be controlled in the Survey Mode.

2

To activate the Survey mode do the following: 3

1) Turn the System Four “On” by selecting either Elevation or Slope Control.

1) Serial Number Plate - The Serial Number Plate contains your System Four’s part number and serial number.

2) Momentarily press the Auto/Manual/Survey (Cal) Switch down.

2) 11 Pin Cable Connector - Power and signal communications between System Four components travel via this connector.

The Control Box will beep one time and the Grade Correction Display will show a flashing, circular pattern . The LCD Display will now show the correct elevation if Elevation Control has been selected or the current slope if Slope Control has been selected.

3) Audible Beeper - When the power is turned on, or calibration selections are made, the beeper will sound. The beeper may be turned Off or On using the Beeper Calibration Mode (see Accessing System Four Performance Settings later in this chapter).

To return to the Control mode: • Momentarily press the Auto/Manual/Survey (Cal) Switch again (less than 2 seconds) then place in Auto.

4) Mounting Knob - The Mounting Knob is used to secure the Control Box to its mounting bracket. The mounting stud is permanently 21048 (12/95)

The system will be returned to the normal Control mode and grade will automatically be set to On Grade. 12

Operation & Maintenance Manual

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System Four Grade and Slope Automation Calibrating the Tracker or Slope Sensor (changing numbers only) Once the Control Box is powered On by selecting Elevation or Slope Control, pressing the Auto/ Manual/Survey (Cal) Switch down to Survey (Cal) continuously places the unit in the Display Setting Mode and under Manual Control.

Switch while a particular Performance Setting is displayed will select that Setting for adjustment. NOTICE: The recommended, or ”typical” values listed in some of the Performance Settings to follow are meant to be suggested starting points for those settings. If your machine does not perform properly within those recommended values, adjust that setting accordingly until satisfactory performance of your machine is reached.

NOTICE: Turing the Grade Adjustment Knob with the Auto/Manual/Survey (Cal) Switch depressed enters the display setting mode instantly, without the 2 second wait.)

NOTICE: Because of the potential to seriously affect System Four performance and accuracy, three System Four Performance Settings may be “locked-out’ by a Cedarapids authorized technician once the correct values for these Settings are set for your paver. These Settings are Units, Deadband, and Valve Offsets. If you feel further adjustments to these Settings are required, contact your Cedarapids Inc. representative.

As long as the Auto/Manual/Survey (Cal) Switch is depressed, the arrows around the Grade Adjustment Knob will flash. The LCD can be set to any reading by turning the Grade Adjustment Knob. Releasing the Auto/Manual/Survey(Cal) Switch stores the LCD reading and sets system control to On Grade. To return to Automatic Control, push switch up. If Elevation Control has been selected, the elevation displayed is set by this process. If Cross Slope has been selected, cross slope calibration is set.

Continue to hold the Auto/Manual/Survey (Cal) Switch down and turn the Grade Adjustment Knob

Accessing System Four Performance Settings With the screed remote Man/Setup/Auto switch in SETUP, continuously pressing the Auto/Manual/ Survey (Cal) Switch on th econtrol box down when powering the System Four On (selecting Elevation Control or Slope Control) allows access to the System Performance Settings. These settings are Blank, Gain (Elevation), Gain (Slope), Units, Slope Resolution, Beeper, Hour Meter Deadband, Valve Offsets and units.

AUTO M A N SURVEY (CAL)

OR

Continuously Holding Switch Down

+

= Turn Knob One "Click" to the Right

System Four

Sonic Tracker III Gain Calibration (first of 8 calabration modes)

While Turning Power ON

one click at a time to access the other Performance Settings. Releasing the Auto/Manual/Survey (Cal) Switch will display the current system settings. Turning the Grade Adjustment Knob one click at a time will change the settings.

When the Performance Setting menu is entered at start-up, the arrows around the Grade Adjustment Knob will flash. Rotating the Grade Adjustment Knob clockwise scrolls the LCD display through the System Performance Settings in the order listed above. Releasing the Auto/Manual/Survey (Cal) 21048 (12/95)

+

NOTICE: The Blank Screen must be displayed to exit and SAVE changes made to the System Performance Settings 13

Operation & Maintenance Manual

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System Four Grade and Slope Automation 1) Blank Screen The Blank Screen will be the first setting displayed when entering the System Performance Settings and must be displayed to exit and save the System Performance Settings.

to the main System Performance Settings menu. You may now rotate the Grade Adjustment knob to access another Performance Setting or exit the System Four Performance Settings menu by rotating the Grade Adjustment Knob until the Blank Screen is displayed and releasing the Auto/Manual/Survey (Cal) Switch.

2) Gain (Elevation) This setting determines the speed at which System Four will cause the Tow Point Cylinders to adjust to a change in elevation.

3) Gain (Slope Control) This setting determines the speed at which System Four” will cause the Tow Point Cylinders to adjust to a change in slope.

When the Sonic Tracker II senses a change in elevation, the Control Box takes that information and makes a determination as to how far from On

SystemFour

SystemFour

+

When the Slope Sensor senses a change in slope, the Control Box takes that information and makes a determination as to how far from On Grade the screed currently rests.

Grade the screed currently rests. The Control Box will then send a signal to the paver valve to open a pre-determined amount, returning the screed to the desired grade at a certain speed. The Gain (Elevation) setting allows the paver operator to set Sonic Tracker II so that the paver valve opens a pre-determined amount allowing the screed to react (adjust to the change in elevation) faster or slower. The objective is to set the Gain so the screed reacts to the change in grade quickly, but without “overshooting” the new elevation.

The Control Box will then send a signal to the paver valve to open a predetermined amount, returning the screed to the desired slope at a certain speed. The Gain (Slope) setting allows the paver operator to set System Four so that the paver valve opens a predetermined amount allowing the screed to react (adjust to the change in slope) faster or slower. The objective is to set the Gain so the screed reacts to the change in slope quickly, but without “overshooting” the new slope.

When chosen, the Gain symbol along with the Sonic Tracker II and Laser symbols are displayed until the Auto/Manual/Survey (Cal) Switch is released. The percentage gain, 1 % to 100%, is then displayed. The arrows around the Grade Adjustment Knob flash.

The Gain Symbol along with the + Slope and - Slope symbols are displayed until the Auto/Manual/Survey (Cal) Switch is released. The percentage gain, 1 % to 100%, is then displayed. The arrows around the Grade Adjustment Knob flash.

The typical Gain setting for the Tracker is 25%.

The typical gain setting for the Slope is 25%.

After the desired value is selected by turning the Grade Adjustment Knob pressing and holding the Auto/Manual/Survey (Cal) Switch stores the value into the Control Box memory and returns the LCD 21048 (12/95)

After the desired value is selected by turning the Grade Adjustment Knob Pressing and holding the Auto/Manual/Survey (Cal) Switch stores the value 14

Operation & Maintenance Manual

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System Four Grade and Slope Automation into the Control Box memory and returns the LCD to the main System Performance Settings menu. You may now rotate the Grade Adjustment knob to access another Performance Setting or exit the System Four Performance Settings menu by rotating the Grade Adjustment Knob until the Blank Screen is displayed and releasing the Auto/Manual/Survey (Cal) Switch.

SystemFour

After On or Off has been selected by turning the Grade Adjustment Knob, pressing and holding the Auto/Manual/Survey (Cal) Switch stores the value into the Control Box memory and returns the LCD to the main

4) Slope Resolution (Sets display to read in increments of .1 % or to .01 %)

System Performance Settings menu. You may now rotate the Grade Adjustment knob to access another Performance Setting or exit the System Four Performance Settings menu by rotating the Grade Adjustment Knob until the Blank Screen is displayed and releasing the Auto/Manual/Survey (Cal) Switch.

The is displayed until the Auto/Manual/Survey (Cal) Switch is released. The arrows around the Grade Adjustment Knob flash and rotating the knob cycles the display between a resolution of . 1 % and .01%.

SystemFour

6) Hour Meter (Displays Total and Auto Hours) The Hour Meter symbol is displayed until the Auto/Manual/Survey (Cal) Switch is released. The arrows around the Grade Adjustment Knob flash and rotating the knob cycles the display between total hours System Four has been powered On, and hours System Four has been under automatic control. Auto hours are represented by a colon (:) preceding the number.

Slope Resolution should be set to .1% (tenths) for paving applications. After the desired resolution is selected by turning the Grade Adjustment Knob, pressing and holding the Auto/Manual/Survey (Cal) Switch stores the value into the Control Box memory and returns the LCD to the main System Performance Settings menu. You may now rotate the Grade Adjustment knob to access another Performance Setting or exit the System Four Performance Settings menu by rotating the Grade Adjustment Knob until the Blank Screen is displayed and releasing the Auto/Manual/Survey (Cal) Switch.

SystemFour

After viewing the desired hours by turning the Grade Adjustment Knob, pressing and holding the Auto/ Manual/Survey (Cal) Switch returns the LCD to the main System Performance Settings menu. You may now rotate the Grade Adjustment knob to access another Performance Setting or exit the System Four Performance Settings menu by rotating the Grade Adjustment Knob until the Blank Screen is displayed and releasing the Auto/Manual/Survey (Cal) Switch.

5) Beeper (Sets audible beep On or Off) The Beeper symbol is displayed until the Auto/ Manual/Survey (Cal) Switch is released. The arrows around the Grade Adjustment Knob flash and rotating the knob cycles the display between On and Off. 21048 (12/95)

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System Four Grade and Slope Automation 7) Deadband (Sets On Grade Deadband)

8) Valve Offset The Valve Offset setting controls the duration of the signal sent to the paver valves from the Control Box. If the signal is to short in duration, the operator will hear the paver valve “clicking” but the cylinder will not move. Like wise, if the signal is too long in duration the valve will “spring” wide open causing the cylinder to jump and overcorrect.

Deadband is the area of the Working Window that is On Grade and simply means that while the reference is within that area, the pavers valves are idle (closed). Therefore the wider the Deadband (On Grade area), the more a reference can move up or down without a correction being initiated.

SystemFour

SystemFour

To set the Valve Offset release the Auto/Manual/ Survey (Cal) switch. The LED display will momentarily display the letters “CAL” and then back to “OFS”

When Deadband is added or taken away from the On Grade region of the working window, it takes this extra area from the Fine Correction region (.6" above or below On Grade). It Does Not add this distance to the overall working window height.

SystemFour

NOTICE: The amount of Deadband should be carefully selected so that constant hunting of the screed (rising up and down) is prevented. Press the Auto/Manual/Survey (Cal) switch to Survey (Cal) and Release.

The Deadband symbol is displayed until the Auto/ Manual Survey (Cal) Switch is released. The arrows around the Grade Adjustment Knob flash. Rotating the knob cycles the display between 0 and 15. The number displayed represents the Deadband (On Grade area) in millimeters.

SystemFour

The typical Deadband setting is 3 mm. After the desired value is selected by turning the Grade Adjustment pressing and holding the Auto/ Manual/Survey (Cal) Switch stores the value into the Control Box memory and returns the LCD to the main System Performance Settings menu. You may now rotate the Grade Adjustment knob to access another Performance Setting or exit the System Four Performance Settings menu by rotating the Grade Adjustment Knob until the Blank Screen is displayed and releasing the Auto/Manual/Survey (Cal) Switch. 21048 (12/95)

This causes the current offset in the up direction to be displayed and shows a UP light indicator. Turning the Grade Adjustment Knob adjusts the rate at which the tow point cylinder moves.

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System Four Grade and Slope Automation NOTICE: The control boxes should be marked and used on the same side of the machine the Valve Offset was set for as setting may vary from left to right sides. 9) Unit (Sets display to read in feet, inches, or centimeters) The Unit symbol is displayed until the Auto/Manual/ Survey (Cal) Switch is released. At switch release, the current unit of measure is displayed. The arrows around the Grade Adjustment Knob will flash and rotating the knob cycles through the units of Feet, Inches and Centimeters.

Adjust the Grade Knob until No cylinder movement is noted and then adjust to the point where a slight cylinder movement is noted. Press the Auto/Manual/Survey (Cal) switch to Survey (Cal) and Release.

SystemFour SystemFour

The Units should be set to Inches or Centimeters. (Feet settings are not used in paving applications.)

This causes the current offset in the up direction to be displayed and shows a DOWN light indicator.

After the desired unit of measure is selected by turning the Grade Adjustment Knob, pressing and holding the Auto/Manual/Survey (Cal) Switch stores the value into the Control Box memory and returns the LCD to the main System Performance Settings menu. You may now rotate the Grade Adjustment knob to access another Performance Setting or exit the System Four Performance Settings menu by rotating the Grade Adjustment Knob until the Blank Screen is displayed and releasing the Auto/Manual/ Survey (Cal) Switch.

Turning the Grade Adjustment Knob adjusts the rate at which the tow point cylinder moves.

Adjust the Grade Knob until No cylinder movement is noted and then adjust to the point where a slight cylinder movement is noted.

Sonic Tracker II The Sonic Tracker II measures the distance to a Control Reference. It can be set to maintain a specific elevation above a given control reference (Ski, Stringline, Curb or Gutter, Existing Mat, etc.).

After the desired value have been selected Press the Auto/Manual/Survey (Cal) switch to Survey (Cal) and hold while turning the Grade Adjustment Knob to the next performance setting.

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See “Sonic Tracker II: How It Works”.

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System Four Grade and Slope Automation Sonic Tracker II Front Panel The Sonic Tracker II- front panel contains an LED display similar to the Control Box as well as a Bail Sensor LED:

(6.1 cm) of On Grade. Slowly flashes when beyond 2.4" (6.1 cm) of On Grade The Sonic Tracker II- Grade Correction LED’s and the Control Box Grade Correction LED’s will simultaneously display the same symbols during operation.

2

2) Sonic Tracker II Bail LED In the upper right corner of the Sonic Tracker II face plate is a small symbol used to represent the use of the Sonic Tracker II Bail. This LED symbol will

1

TOPCON

T automatically illuminate when the Bail is attached to the Sonic Tracker II (see Sonic Tracker II Bail- later in this chapter). 1) Grade Correction Display The Sonic Tracker II Grade Correction Display, like the Control Box, cues you when the grade level is Too High, On Grade or Too Low: Too High (lower tow point to reach grade). Flashes when within .6" (1.5 cm) of On Grade. Solid when greater than .6" (1.5cm) but less than 2.4" (6.1 cm) of On Grade. Slowly flashes when beyond 2.4" (6.1cm) of On Grade Sonic Tracker II Rear The Sonic Tracker II rear contains the areas for mounting and System Four hook up, as well as a temperature sensor.

On Grade - At correct grade.

1) Mounting Access - The Sonic Tracker II Mounting Access mates to a bracket on the paver ( Installation).

Too Low (Raise tow point to reach grade). Flashes when within 6" (1.5 cm) of On Grade. Solid when greater than .06" (1.5cm) but less than 2.4" 21048 (12/95)

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System Four Grade and Slope Automation 2) Serial Number Plate - The Serial Number Plate contains your Sonic Tracker II’s part number and your Sonic Tracker II serial Number.

1) With the Sonic Tracker II laying face up on a flat surface, gently pull outward on the Bail forks until they just clear the lower “Skirt” of the Sonic Tracker II.

3) 11 Pin Connector - Power and signal communications between the Sonic Tracker II and the Control Box travel via this connector.

NOTICE: Do Not pull the bail forks out far enough to permanently bend them. Repeated bending will weaken the bail resulting in breakage or a bail that will not stay affixed to the Sonic Tracker II.

4) Temperature Sensor - The Temperature Sensor is used to compensate for air temperature changes during non-paving operations. When the Sonic Tracker II Bail is in place, this sensor is overridden by the Bail. Sonic Tracker II Bail The Sonic Tracker II Bail is used to compensate for the rapid air temperature changes that can occur while paving.

2) Making sure the rubber material is all the way to the bail fork ends, place the fork ends in the existing holes in each side of the Sonic Tracker II.

The Sonic Tracker II transducer sends out sound pulses. These pulses bounce off of a physical reference (Ski, Stringline, Curb or Gutter, Existing Mat, etc.) and return to the transducer at the speed of sound. The speed at which these pulses hit the reference and return are affected by the air temperature they travel through, slower through cooler air, and faster through warmer air. The Sonic Tracker II Bail provides a constant physical reference for the Sonic Tracker II to calibrate the speed of sound, thus avoiding effects caused by rapid fluctuations in air temperature over freshly laid asphalt (see Sonic Tracker II How It Works).

3) Once the Bail fork ends are set in the existing holes, gently squeeze the bail forks into the securing slots. Make sure the ends have securely “snapped” into place.

Sonic Tracker II Bail Installation Mount the Bail to the Sonic Tracker II using the following procedures:

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System Four Grade and Slope Automation Sonic Tracker II Components

the Transducer can be easily removed, and a new Transducer installed returning the Sonic Tracker II to its original condition.

SONIC TRACKER II 46062-551-09

Sonic Tracker II Transducer Replacement (see: Maintenance and Parts)

O-RING PART OF KIT 46062-551-02-02 SCREW PART OF KIT 46062-551-02-02

Slope Sensor The Slope Sensor “reads” slope using an internal precision level. It works by reading the lateral inclination (right side to left side tilt, or left side to right side tilt) of the screed.

TRANSDUCER ASSEMBLY PART OF KIT 46062-551-02-02 RETAINING RING

FILTER PART OF KIT 46062-551-02-02 BOX OF FILTERS 46061-551-02-03

1) Sonic Tracker II Transducer NOTICE: If the Sonic Tracker II is experiencing erratic or inconsistent readings, Transducer contamination should be considered first before assuming any other type of failure. The most common sign of Transducer contamination is the ability of the Sonic Tracker II See the ground, but not a Fixed Stringline or the Bail.

T

P O

C

O

N

SLOPE SENSOR 46061-551-18

The Transducer operates by generating sound pulses. This is done by sending an electrical charge through a very thin piece of metallic material which vibrates rapidly creating the sound pulse. When oily or moisture laden particles stick to this metallic material it reduces its ability to vibrate therefore reducing the strength of the sound pulse.

Unlike the Sonic Tracker II, the Slope Sensor is a sealed unit and contains no adjustments or user serviceable parts. Once the Slope Sensor is mounted to the paver, all calibration and/ or operating displays are represented on the Control Box. The Slope Sensor contains no displays or adjustments and once the Slope Sensor is mounted to the paver, it is not removed.

NOTICE: During normal operation, the Sonic Tracker II should always have the small piece of Filter Foam over the Transducer assembly. This Filter Foam” will trap most of the contaminants that can foul the Transducer. This Filter Foam’ should be replaced at least every month.

Junction Box The primary function of the Junction Box is to route power and ground from the paving machine to the Control Box, and to route correction signals from the Sonic Tracker II and Slope Sensor to the Control Box. It also routes valve signals from the Control Box to the paving machine.

Over an extended period, very fine particles can pass through the Filter Foam and stick to the Transducer slowly reducing its sound pulse. When this happens 21048 (12/95)

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System Four Grade and Slope Automation

CEDARAPIDS

MAT THICKNESS EXTEND

INCREASE

2.

SLOPE

DECREASE

JUNCTION BOX 46061-551-19

MATCH HEIGHT UP

MAN

1.

DOWN MAT THICKNESS

SET-UP

INCREASE

DECREASE

STOP

MAN SET-UP

STOP

FEED STOP

The Junction Box is a sealed unit and contains no adjustments or user serviceable parts. It allows for quick and easy attachment and removal of the system cables, and once installed on the paving machine it is not removed.

OVER RIDE

1) The MAN/SET-UP/AUTO controls the function modes listed:

Power & Interlock (Screed Remote Controls) Located on the left and right Screed Remote Control boxes are two switches that provide manual operation of the tow point cylinders or allow function of the System Four automation. The left and right Mat Thickness switches are independent of each other and control only the tow point function of its respective side.

• MAN/SET-UP/AUTO switch in MAN mode: Power is provided to the INCREASE/ DECREASE switch. The System Four automation will not control the tow point cylinder in this mode(isolation relay is open). • MAN/SET-UP/AUTO switch in SET-UP mode: The System Four automation can drive the tow point cylinder with the paver stopped or moving (isolation relay is closed). The INCREASE/DECREASE switch will not work in this mode. • MAN/SET-UP/AUTO switch in AUTO mode: Function of the System Four automation is interlocked to the travel system. When the paver is moving forward, the isolation relay is closed the automation is allowed to drive the tow point cylinder. As the travel lever (s) or the

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System Four Grade and Slope Automation

CABLE Coil Cord junction box to Burner 46061-551-21

CABLE Coil Cord junction box to Burner 46061-551-21

LH Isolation Relay (46325-001-52) located inside console

RH Isolation Relay (46325-001-52) located inside console

Forward/Neutral/Reverse switch are placed in neutral or the brake switch is engaged. The isolation relay is opened, preventing the automation from driving the tow point cylinder.

1) Solenoid Valve: Used to direct hydraulic fluid to either the rod or base ports of the tow point cylinder. The valve has a manual override on each end for trouble-shooting purposes.

2) The INCREASE/DECREASE switch allows manual positioning of the tow point cylinder when the MAN/SET-UP/Auto switch is in the MAN mode.

2) Dual Throttle Valve: Used to set cylinder travel speed for both directions to 18 seconds. 3) Holding Valve: Used to hydraulically lock the tow point cylinders.

Burner Control Console Components The Burner Control Console has cable connection points on the top LH & RH to connect the System Four junction box to the respective tow point solenoid valve.

Left Tow Point Valves

LH Front Bulkhead Valves

The isolation relays for each side are located inside the console.

3.

Tow Point Valves Right Tow Point Valves

2. RH Front Bulkhead Valves

1. 1) Solenoid Valve: Used to direct hydraulic fluid to either the rod or base ports of the tow point cylinder. The valve has a manual override on each end for trouble-shooting purposes.

3.

2) Dual Throttle Valve: Used to set cylinder travel speed for both directions to 18 seconds.

2.

3) Holding Valve: Used to hydraulically lock the tow point cylinders.

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System Four Grade and Slope Automation Solenoid Valve Din Connectors Red LED (light) located inside each connector

Din Connectors

Manual Override Buttons

Each solenoid valve electrical connector (Din Connector) has a red LED (light) located inside the clear connector cap. This LED is used for troubleshooting purposes.

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System Four Grade and Slope Automation Getting Started This chapter is designed to get the operator started using System Four. Before starting however, decisions have to be made as to the type of control to be used Sonic Tracker II for longidudinal grade elevation, or Slope Sensor for controlling transverse slope and whether the controls should be placed to enhance rideability or build profile, see “Building Rideability or Profile”.

Place Tracker II 14" above reference

If elevation control is to be used, a control reference must be decided upon (Fixed Stringline”, Surface String, Existing Mat, Ski etc.). (For information on setting control references, see “Control References”.

Target Sonic Tracker II Over Target Reference (ski, stringline, curb, or existing mat)

Target Reference

4) Turn the Grade Adjustment Knob on the Control Box in the direction the arrows indicate until the On Grade Bar comes on:

Once these factors have been chosen and System Four has been installed on the paver use the following steps to Null and Calibrate the System Four and begin a paving session. Getting an On Grade Bar: (NULLING) Sonic Tracker II Control To set the Sonic Tracker II to “On Grade” or “Null”: AUTO M A N

OR UNTIL=

1) Set the Auto/ Manual/Survey switch to Manual

SURVEY (CAL)

OR:

2) Make sure that the Power Switch is set to Sonic Tracker Control

a) Momentarily hold the Auto/Manual/Survey switch down until it beeps (This will place the Control Box in the Survey mode) b) Momentarily hold the switch down again until it beeps (This will place the Control Box back to the control mode (NULL) and the “On Grade” Bar will be set)

3) Place the Sonic Tracker II over the control reference

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System Four Grade and Slope Automation

AUTO M A N

+

=

BEEP

&

SURVEY (CAL)

THEN

OR UNTIL=

AUTO M A N

=

BEEP

&

SURVEY (CAL)

For more information on Control Box settings see Functions. Slope Control To set the Slope Control to “On Grade” or “Null”: AUTO M A N

OR A) Momentarily hold the Auto/Manual/Survey (Cal) switch down until it beeps (This will place the Control Box in the Survey mode)

1) Set the Auto/ Manual/Survey (Cal) switch to Manual

B) Momentarily hold the switch down again until it beeps (This will place the Control Box back to the control mode and the “On Grade” or (“NULL”) Bar will be set)

SURVEY (CAL)

2) Make sure that the Power Switch is set to Slope Control

AUTO M A N

+

=

BEEP

&

SURVEY (CAL)

THEN AUTO M A N

NOTICE: Only one side of the paver should be in the slope mode. 3) Turn the Grade Adjustment Knob on the Control Box in the direction the arrows indicate until the On Grade Bar comes on:

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=

BEEP

&

SURVEY (CAL)

For more information on Control Box settings Functions.

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System Four Grade and Slope Automation Setting Control Box Display (Changing Numbers ONLY): Sonic Tracker II Control

3) While holding the Auto/Manual/Survey (Cal) switch down, turn the grade adjustment knob until the slope being laid is displayed

To set the Control Box Display to a desired number:

M A N

1) Follow instructions listed in “Getting an On Grade Bar: (NULLING)” to get the Tracker II over the control reference and get it NULLED (on grade bar showing).

M A N

+

%

4) Release the Auto/Manual/Survey (Cal) Switch. The slope entered will remain on the display and the “On Grade” symbol will be.

=

SURVEY (CAL)

5) Place Auto/Manual/Survey (Cal) Switch in Auto mode.

3) Release the Auto/Manual/Survey (Cal) Switch

NOTICE: When using slope control, never adjust the screed using the manual hand cranks. Adjustments using the hand cranks will require re-calibrating the Slope Sensor.

4) The number entered will remain on the display and the “On Grade” symbol will be set 5) Place Auto/Manual/Survey (Cal) Switch in Auto mode.

Getting Started Paving

NOTICE: The number display does not necessarily reflect mat depth being placed and should not be used to control depth.

1) Pre-heat the screed to the temperature of the material being delivered. A cold screed bottom will tear and drag causing the mat depth to be lower than desired (a depression).

NOTICE: When using grade control, never adjust the screed using the manual hand cranks.

2) If a transverse joint is to be created the quality and durability of the joint depends on careful preparation of the existing mat or lane. It is critical that any taper or defective area be removed. The joint area has to be perfectly flat and parallel with the line of paving! If not, a depression or bump will be produced. Refer to “Transverse Joint” in this chapter

Slope Sensor Calibration To Calibrate the Slope Sensor (Change number readout to reflect percentage of slope being placed): 1) Pave manually using screed depth cranks until desired percentage of slope has been established 2) Follow instructions listed in “Getting an On Grade Bar: (NULLING)” to get the slope control NULLED (on grade bar showing).

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=

NOTICE: Make sure to enter a positive slope if the grade slopes Up to the right and a negative slope if it slopes Down to the right

System Four

+

+

SURVEY (CAL)

2) While holding the Auto/Manual/Survey (Cal) Switch down, turn the grade adjustment knob until the desired number is displayed AUTO

System Four

AUTO

3) Set initial tow point height in relation to mat depth. Refer to “Line of Pull” in this chapter.

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System Four Grade and Slope Automation Line of Pull Applied Parallel to the Line of Paving

Place Tracker II 14" above reference

4) Nulling the screed is traditionally done with the use of boards that equal the desired loose mat depth. Then a given amount (1¦8” to 1¦4”) of nose up attitude is introduced to the screed. The boards needed should be equal to the thickness of the loose or unrolled mat. The number need will depend the width the screed is set up to pave at. Generally 2 boards at 10' wide, 4 boards at 20' and etc. The length of each board should be such that the screed bottom is fully supported from front to tail when set on the boards.

Target Reference

8) Null the Control Box (s) to get an on grade bar. Refer to “Getting an ON Grade Bar (Nulling)“ in this chapter. 9) Place the Auto/Manual/Survey switch(s) in Auto and begin paving. After the machine has traveled at least a few feet, measure the mat thickness. Make mat thickness changes by making small adjustments using the Grade Adjustment Knob.

5) Null the screed, then manually preset the angle of attack. Refer to “Nulling the Screed” in this chapter 6) Fill auger chamber to exactly 1/2 an auger level. Hand filling outboard ends of the screed to prevent force feeding.

Controlling Yield

Take at least 5 checks about 5 foot apart and average the checks. DO NOT adjust the screed depth after each check. Doing so will produce a rough riding surface. Remember the purpose of a paver is to place a flat mat over an irregular grade.

7) Place the Sonic Tracker II(‘s) 14 inches over the control reference. Refer to “Control References” in this chapter.

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Target Sonic Tracker II Over Target Reference (ski, stringline, curb, or existing mat)

NOTICE: For best performance, make only small adjustments and let the paver move several machine lengths before making another adjustment.

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System Four Grade and Slope Automation material & material design. Once the compaction rate has been determined and the correct thickness of lath has been acquired, place the lath at the edge of the joint to elevate & support the screed to the correct starting level.

NOTICE: When using slope control, never adjust the screed using the manual hand cranks. Adjustments using the hand cranks will require re-calibrating the Slope Sensor. Once satisfactory mat thickness has been reached, you may want to set the Control Box LCD (Elevation) to display that mat thickness.

Place boards or lath that equal the compaction rate of the material from thickness of the joint.

The paver will now maintain the desired mat thickness until another change is desired or the job is completed. Transverse Joints Transverse joints are created when an existing mat or lane is to be continued. The quality and durability of the joint depends on careful preparation of the existing mat or lane. It is critical that any taper or defective area be removed. The joint area has to be perfectly flat and parallel with the line of paving! If not, a depression or bump will be produced.

2) Back the paver up over the joint and align the screed so the face or mold board is square with the edge of the joint. Lower the screed onto the boards or lath and adjust the screed depth cranks so the screed is resting flat on the boards.

Joint Preparation An existing mat should be checked and the tapered area removed to produce a joint area that is flat and parallel with the line of paving.

Null Screed (No angle of attack)

Checking the existing mat with a good straight edge

Remove

3) Using the screed depth cranks, introduce approx. 1/8" to 1/4" initial angle of attack.

1/8" to 1/4" Angle of Attack

Proper joint area after removing taper

Nulling the Screed 1) Place boards or lath that equal the amount of compaction in the joint area. Remember compaction rates change due to thickness of 21048 (12/95)

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Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation 4) The auger chamber should be filled to no more than 1/2 an auger level. Do Not over fill the auger 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.

We see above a thin mat being placed, but the initial tow point setting is extremely high. In this condition the towing forces are being applied at a upward angle, increasing the lift forces applied to the screed. To maintain a given depth, the angle of attack must be decreased to compensate for the increased lift. The screed is now running with a slight nose down attitude. Only the front portion of the screed is compacting & finishing the material being placed, causing poor mat texture & extreme wear at the front portion of the screed bottom. Also, when the screed stops, it will have more of a tendency to rock or teeter as the tractor relaxes the tension on the screed. This could increase the amount of settling & deviations introduced to the mat. Building Rideability or Profile Evaluation of Jobs

Line of Pull The Line of Pull refers to the angle at which the screed is being towed forward. Best results occur when the towing force is applied relatively parallel to the grade. To do this we set the tow point cylinders in relation to the general depth we will be paving. Line of Pull Applied Parallel to the Line of Paving

Evaluation of specifications and grade conditions on a job is extremely important if the paver and automation are to be configured properly to produce the desired or required results. Failure to properly configure the screed and automation for each phase of the paving operation, or specific conditions, will result in producing a road that is unsatisfactory or will not meet specifications. Just as one size of shoe does not fit everyone, one configuration of the screed and automation will not produce superior results in all conditions and jobs. Building Profile

Rule of Thumb: Thin mats will require a lower initial tow point setting, while thicker mats will require a higher initial tow point setting.

The screed inherently resists immediate changes in depth or slope and averages changes over approximately five lengths of the tow arm. Job specifications that require an exact profile (thickness of material and or slope) at any given point in the grade, require the screed to react very quickly to maintain it’s position in relation to the established line of grade and or percentage of slope. Very simply, when building profile we are over correcting the screed to force it into changing depth very quickly to maintain exact thickness and or slope at

Line of Pull Applied Upwards Can cause the screed to run with a nose-down attitude.

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29

Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation given points in the grade. Building for profile is not necessarily building a smooth rideable surface, as any changes will be introduced very quickly.

Effective Length of Tow Arm Automation sensors will always move the tow point up or down to maintain the sensors null point, in effect the location of the sensor becomes our control point. The tow point becomes only a point from which we raise or lower the tow arm to reestablish the null point at the sensor. The effective length of tow arm becomes the distance between the control point (sensor) and the pivot point (trailing edge of the screed). Because the screed must travel 5 tow arm lengths to fully react to a correction, shortening the effective tow arm length shortens the distance the paver must travel to complete a correction, therefore increasing reaction time. Moving the sensor towards the screed increases reaction time (builds profile), while moving the sensor towards the tow point decreases reaction time (builds rideability).

Building for profile is desirable on jobs where two or more layers of pavement will be placed or where exacting slopes (transitions & super elevations) have to be built or maintained. By reestablishing or building the desired profile of a road on the first layer, all other layers can be built for rideability or smoothness. Rideability When building for rideability, automation enhances the screeds resistance to immediate changes, producing a very smooth riding surface. Very simply, when building for rideability we are taking a given change and stretching that change over a long area to produce a superior riding surface. Building for rideability is desirable where job specifications place a high emphasis on the smoothness of the finished job. On jobs where two or more layers of pavement will be placed, the first layer should be built for profile to get the grade and slope to proper elevation specifications. All other lifts should be built for rideability, to smooth out any deviations from the previous lift.

Profile (Rearward)

Rideability (Foreward)

Effective Tow Arm Length

NOTICE: Never mount Tracker II behind the center line of the augers. This could cause severe over-correction.

Sensor Positioning The position of the sensor on the tow arm determines how fast the screed will react to a change of the null point at the sensor. By positioning the sensor, we can build profile or rideability. We need to evaluate job specifications and grade related conditions to determine the desired mounting position that will produce the required results.

Control References Grade Control (Joint Matching) Joint matching or matching the height of the mat being placed to an existing mat or curb, requires the screed to be very responsive to any changes in the elevation of the existing mat or curb. This is an application where we are building “Profile”, or over-correcting the screed, forcing it change depth in a very short distance.

Rule: Sensor(s) mounted 1/4 the tow arm length back from the tow point builds RIDEABILITY. Sensor(s) mounted inline with the augers builds PROFILE.

The grade sensor should be mounted 3/4 of the way back from the tow point, or just ahead of the augers. 21048 (12/95)

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Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation conditions will not permit running a ski beside the screed. When paving at wide widths the over the screed ski is mounted in close to the tractor, the reference system being close to the tractor, provides the automation a more precise reference in relation to tow point deviations caused by grade conditions, by virtue of being mounted close to the tractor. Problems of flexing mounting hardware simply do not exist due to the close mounting position. The Cedarapids Over the Screed Ski system provides a true independent mounted ski reference system that is not effected by the tractor traveling over irregular grades and provides a very consistent reference plane for the grade sensory system.

With the sensor mounted close to the screed, it is very responsive to any deviation in the screeds position, though not very responsive to deviations of the tow point position, caused by the tractor traveling over irregular grades. Therefore it is not anticipating these deviations , it can only react when a deviation of the tow point position affects the position of the screed. Grade Control (Ski) When using automation off a ski, corrections to deviations that occur at the sensor or the screed, will require the paver to travel approximately 5 lengths of the tow arm before the correction is fully completed. Deviations that occur at the tow point, due to the tractor traveling over irregular grades, are corrected for immediately. In effect the sensor is correcting for deviations at the tow point before they can affect the screeds angle of attack (position). In this application we are building “Rideability”, or averaging all required changes in depth over a longer area.

Mount the Sonic Tracker II 14 inches above the top wire. A piece of 1/8” tubing should be placed over the wire to increase its reflective surface for best results.

The grade sensor should be mounted 1/4 of the way back from the tow point. With the sensor mounted in the forward position, any deviation at the tow point caused by the tractor traveling over irregular grades, will cause the sensor to react immediately, to correct for that deviation. Therefor maintaining the same tow point position (angle of attack on the screed) in relation to the reference (ski), regardless of the grade irregularities.

14" Ski Wire

Averaging Ski

1/8" Tubing Or Tape Wraped

Over the Screed Ski The over the screed ski is the preferred reference system when paving wide widths or where job 21048 (12/95)

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Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation Existing Surface

Surface Stringline

The Sonic Tracker II can follow nearly any existing surface. Simply place the Sonic Tracker II 14 to 24 inches above the surface. Get an On Grade Bar (Refer to “Getting an On Grade Bar Sonic Tracker II Control “ earlier in this chapter), switch the Control Box to Auto and start paving.

A Surface Stringline is stretched over a given length of grade. It rests on the high places and bridges the low, creating an average over a distance as long as 1500 feet. Since the Sonic Tracker II is noncontacting, it can track Surface Stringline without deflecting it, producing an average of the surface. Surface Stringlines can produce acceptable results in low specification type jobs, but traditionally are not used in very demanding or high specification jobs.

Notice: Using automation to follow existing surfaces is NOT RECOMMENDED as every deviation in the existing surface will be introduced into the mat being placed.

Once Surface Stringline is in place, all you need to do is line up the Sonic Tracker II 14 to 18 inches above the string, get an On Grade Bar and switch to Auto.

Curb or Gutter A curb or gutter that is poured before paving can be used as a reference. Simply line the Sonic Tracker II 14" above the curb or gutter edge and get an On Grade Bar. Switch the Control Box to Auto and start paving. Notice: Curbs and gutters make a very poor reference if smoothness of the placed mat is of concern. This is due to the variations in elevation along the length of the curb or gutter.

21048 (12/95)

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Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation Slope Conversion Table Slope

Actual Approx. decimal fraction inch per inch per ft. ft.

Inch per 10 ft.

Inch per 11 ft.

Inch per 12 ft.

Inch per 13 ft.

Inch per 14 ft.

Inch per 15 ft.

Inch per 16 ft.

Inch per 17 ft.

Inch per 18 ft.

Inch per 19 ft.

Inch per 20 ft.

0.10%

.012

1/64

1/8

1/8

5/32

5/32

5/32

3/16

3/16

7/32

7/32

7/32

1/4

0.13%

.015

1/64

5/32

5/32

3/16

3/16

7/32

7/32

1/4

1/4

9/32

9/32

5/16

0.20%

.024

1/32

1/4

1/4

9/32

5/16

11/32

3/8

3/8

13/32

7/16

15/32

15/32

0.26%

.031

1/32

5/16

11/32

3/8

13/32

7/16

15/32

1/2

17/32

9/16

19/32

5/8

0.30%

.036

3/64

3/8

13/32

7/16

15/32

1/2

17/32

9/16

5/8

21/32

11/16

23/32

0.40%

.048

3/64

1/2

17/32

9/16

5/8

11/16

23/32

25/32

13/16

7/8

29/32

31/32

0.50%

.060

1/16

19/32

21/32

23/32

25/32

27/32

29/32

31/32

1-1/32

1-3/32

1-1/8

1-3/16

0.52%

.062

1/16

5/8

11/16

3/4

13/16

7/8

15/16

1

1-1/16

1-1/8

1-5/16

1-1/4

0.60%

.072

5/64

23/32

25/32

7/8

15/16

1

1-3/32

1-5/32

1-7/32

1-9/32

1-3/8

1-7/16

0.78%

.093

3/32

15/16

1-1/32

1-1/8

1-7/32

1-5/16

1-13/32

1-1/2

1-19/32

1-11/16

1-25/32

1-7/8

0.80%

.096

3/32

31/32

1-1/16

1-5/32

1-1/4

1-11/32

1-7/16

1-17/32

1-5/8

1-23/32

1-13/16

1-29/32

1.0%

.120

1/8

1-3/16

1-5/16

1-7/16

1-9/16

1-11/16

1-13/16

1-29/32

2-1/32

2-5/32

2-9/32

2-13/32

1.5%

.180

3/16

1-13/16

1-21/32

2-5/32

2-11/32

2-17/32

2-11/16

2-7/8

3-1/16

3-1/4

3-13/32

3-19/32

2%

.240

1/4

2-7/16

2-5/8

2-7/8

3-1/8

3-3/8

3-19/32

3-27/32

4-3/32

4-5/16

4-9/16

4-13/16

3%

.360

3/8

3-5/8

3-31/32

4-5/16

4-11/16

5-1/32

5-13/32

5-3/4

6-1/8

6-15/32

6-27/32

6-3/16

4%

.480

15/32

4-13/16

5-9/16

5-3/4

6-1/4

6-23/32

7-3/16

7-11/16

8-5/32

8-5/8

9-1/8

9-19/32

5%

.600

19/32

6

6-19/32

7-3/16

7-13/16

8-13/32

9

9-19/32

10-3/16

10-13/16 11-13/32

6%

.720

23/32

7-3/16

7-29/32

8-5/8

9-3/8

10-3/32

10-13/16 11-17/32

12-1/4

12-31/32 13-11/16 14-13/32

7%

.840

27/32

8-13/32

9-1/4

10-3/32

10-29/32

11-3/4

12-19/32

13-7/16

14-9/32

15-1/8

8%

.960

32/32

9-19/32

10-9/16

11-17/32 12-15/32

13-7/16

14-13/32

15-3/8

16-5/16

17-9/32

9%

1.08

1-3/32

10-13/16

11-7/8

12-31/32

15-1/8

16-3/16

17-9/32

18-3/8

19-7/32

10%

1.20

1-3/16

12

13-3/16

14-13/32 15-19/32 16-13/16

18

19-3/16

20-13/32 21-19/32 22-13/16

11%

1.32

1-5/16

13-3/16

12%

1.44

1-7/16

14-13/32 15-27/32

14-17/32 15-27/32 17-9/32

14-1/32

17-5/32

18-15/32 19-13/16

21-1/8

22-7/16

18-23/32

20-5/32

23-1/32

24-15/32 25-29/32

21-19/32

23-3/4

All figures in feet are measured horizontally. All figures in inches should be measured vertically and accurately to within 1/32 inch.

21048 (12/95)

33

12

15-21/32 16-13/16 18-1/4

19-3/16

20-17/32 21-19/32 24

25-3/32

26-13/32

27-3/8

28-13/16

Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation Maintenance and Parts

If the Transducer appears to be covered with debris and performance is being affected (see “Lower Sonic Tracker II Components” in Function) replace the Transducer using the steps listed later in this chapter.

This section contains information regarding preventative maintenance and daily care of System Four. Also included are: 1) An Illustrated Parts Guide

Illustrated Parts Guide Using the chart below, match the item number of the part located on the illustration to the item numbers listed on the chart below. The chart is divided into three categories: Component Assemblies, Bracket Assemblies, and Kits. For cable part numbers see “Illustrated Cable Guide” later in this chapter

2) An Illustrated Cable Guide 3) Replacement procedures for the Sonic Tracker II “Transducer” 4) Wiring Diagram Preventative Maintenance & Daily Care A good Preventative Maintenance and Daily Care routine will prevent many problems before they occur. The most important part of Daily Care for System Four is to clean it and keep it free of debris, and to thoroughly dry removable components (Sonic Tracker II’s, Control Boxes, and cables) before storing them in the Carrying Case. In addition, the following procedures will ensure trouble free operation:

Component Assembly Part Numbers

1) Keep the Carrying Case clean and dry. Do not leave it open and exposed to the elements. Clean and dry all components prior to placing them in the Carrying Case.

Part #

Part Description

Qty

2

46061-551-10

Control Box

2

3

46061-551-09

Sonic Tracker II

2

4

46061-551-02-01

Temperature Bail

2

5

46061-551-18

Slope Sensor

1

6

46061-551-19

4-Way Junction Box

2

Bracket Assembly Part Numbers

2) Be sure protective connector caps, provided on the Junction Box, are in place when the cables are not in use. Water accumulating on the connectors can cause electrical shorts.

9

46061-551-11

Asm., Sonic Tracker II Mtg. Bracket

2

10

46061-511-38

Bracket, Tracker End Gat Mtg.

2

11

46061-551-37

Bracket, Tracker Tow Arm Mtg.

2

12

46061-551-27

Arm, Tracker Swing (Short)

2

13

46061-551-28

Arm, Tracker Swing (Long)

2

Kit Part Numbers

3) The components can be used in the rain or light spraying but are not submergible. Do not spray water or use high pressure steam cleaner hoses directly on cables and components. 4) Check the Sonic Tracker II Transducer daily to make sure the Filter Foam and Transducer are clean and free of debris. If the Filter foam is clogged with dirt, replace it (see Illustrated Parts Guide for Filter Foam re-order part number).

21048 (12/95)

Item

34

46061-551-02-02

Kit, Transducer Replacement

1

46061-551-02-03

Filter Foam, Box of 10 Transducer

1

46061-551-12

Kit, .75" Sonic Tracker II Mtg. Bolt

2

Operation & Maintenance Manual

A Terex Company

21048 (12/95)

35

13

12

9

3

4

11

10

5

6

Illustrated Parts Guide

AUTO

2

11

AUTO

12

2

6

13

9

3

4

System Four Grade and Slope Automation

Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation

21048 (12/95)

SONIC GRADE SENSOR

LEFT SOLENOID VALVE & TOW POINT CYL.

36

CONTROL BOX CONTROL BOX

JUNCTION BOX

SLOPE SENSOR

BURNER CONTROL BOX

MAIN JUNCTION BOX

JUNCTION BOX

SONIC GRADE SENSOR

RIGHT SOLENOID VALVE & TOW POINT CYL.

Illustrated Cable Guide Using the chart below, match the item number of the cable located on the illustration to the item numbers listed on the following page.

Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation System Four Cable Numbers

NOTICE: Always remove and discard used O-Rings. Used O-Rings will be distorted and may loose their elasticity due to weather or exposure to diesel fumes.

Cable Part Numbers Item

Part#

1

46061-551-21

Coil Cord, Power

2

2

46061-561-07

Coil Cord Sonic Tracker to Junction Box

2

3

46061-551-08

Cable Control Box to Junction Box (44")

2

46061-551-16

Cable Junction Box to Slope Sensor (3')

1

46061-551-17

Cable Junction Box to Slope Sensor (8')

1

46061-551-20

Cable Junction Box to Slope Sensor (20')

2

4

Part Description

Qty

3) The Transducer can now be gently pulled out. Use a SMALL pair of wire cutters to gently cut the Ty-Wrap then remove the small wire connectors from their tabs. NOTICE: When cutting the Ty-Wrap, be careful not to cut or damage the wires.

Transducer Replacement Procedure NOTICE: If the Sonic Tracker II is experiencing erratic or inconsistent readings, Transducer contamination should be considered first before assuming any other type of failure. The most common sign of Transducer contamination is the ability of the Sonic Tracker II to “see” the ground, but not a Stringline.

4) Place the wire connectors of the new Transducer firmly on their tabs (the gray wire connector is placed on the elevated tab). Place the TyWrap in the slot next to the elevated (gray wire) tab, tighten and trim. DO NOT pinch the wires.

Sonic Tracker II “Transducer” Replacement The only tools needed are a Philips screwdriver and a small pair of cutters. Replace the Transducer as follows:

TRIM EXCESS TY-WRAP

1) Remove and discard the Filter foam (a new Filter foam is provided in the Transducer Replacement Kit).

CAREFULLY PLACE WIRE CONNECTORS ON TABS

PLACE NEW TY-WRAP AROUND WIRES AND TIGHTEN

5) “Feed” the wires back up into the Sonic Tracker II and seat the Transducer into place (the two wire tabs have to sit down into the extra deep area of the recess). Place the new “O”-ring around the Transducer and seat firmly between the Transducer and the Sonic Tracker II Transducer recess.

2) Remove the 4 screws that secure the black Retaining Ring and remove the Retaining Ring, (4 replacement screws are supplied in the Transducer Replacement Kit , but it is advisable to use the original screws and keep the 4 supplied in the kit for replacements in the event one or more are lost). Remove and discard the “O”-Ring (a new O-Ring is supplied with the Transducer Replacement Kit’).

21048 (12/95)

CAREFULLY REMOVE WIRE CONNECTIONS

CUT TY-WRAP

37

Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation 9) Place a NEW Filter Foam over the Transducer. The Sonic Tracker II’ is now ready to return to operation. Connector and Wiring Diagram The electrical diagram shows which wires and pins are used in each components connector.

TRANSDUCER WIRE CONNECTOR PINS

The diagram may also be used to determine the specific part number of a cable needed to connect to a specific paver. Simply find the cable on the diagram, then use the Cable Specification Chart to determine the part number for the cable to your paver.

6) Place the black Retaining Ring over the Transducer assembly with the beveled edges out and the flat surface against the Sonic Tracker II base. Lineup the holes for the mounting screws (the mounting screw holes are set to an irregular pattern. This ensures the retaining ring will only line up with the mounting holes one way). 7) Start the mounting screws into the holes and tighten each until firm. DO NOT OVER TIGHTEN. Use a cross (X) pattern to tighten screws. NOTICE: Over tightening may distort the Transducer metallic material and may crack the Retaining Ring. Use of the O-Ring assures tightness while preventing vibration from loosening the Mounting Screws. NOTICE: DO NOT use Loctite on the mounting screws. Loctite will attack the plastic retaining ring.

8) Make sure no wrinkles in the metallic surface is visible inside the Transducer. If distortion is evident repeat Steps 5 through 8. 21048 (12/95)

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Operation & Maintenance Manual

21048 (12/95)

Connector and Wiring Diagram COMM A

A B C D AUTO/MAN E VBATT F RAISE G VSWITT H J LOWER K GROUND CONFIG L

C O N N

A B C D E F G H 1 J K L

C O N N

CONTROL BOX LEFT SIDE

1

CONTROL BOX RIGHT SIDE

COMM A COMM B AUTO/MAN VBATT RAISE VSWITT LOWER GROUND CONFIG

3

3 A BCDE F G HJ KL CONN 3

A BCDE F G HJ KL CONN 3

39

2

1

CONFIG

H

4

C O N N

JUNCTION BOX LEFT SIDE

2

A B C D E F G H

COMM A COMM B VSWIT GROUND

COMM A COMM B VSWIT GROUND

CONFIG

CONFIG

A B C D E F G H

4

JUNCTION BOX RIGHT SIDE

2

H

COMM A COMM B VSWIT GROUND

CONFIG

2

CONN 1 LKJ HG F E DCBA

CONN 1 A B C D E F G H J KL COMM A COMM A

A B C C O D N N

C O N N

COMM A COMM B

853 OHMS

853 OHMS

COMM A

VSWIT

A B C D E F G

COMM A COMM A

C O N N 2

1

H

C O N N

DUAL PORT SLOPE SENSOR

A B C D E F G

GROUND CONFIG

1

4

A B C D E F G H I

SCREED JUNCTION BOX

C O N N

SONIC TRACKER II

1

RIGHT SIDE

1

H

4

GROUND VBATT RAISE LOWER

A B C D E F G H J K L

A B C D E F G H I

GROUND VBATT RAISE LOWER

JUNCTION BOX CONNECTOR CONN 1 PINOUT A B C D E F G H J K L

COMM A COMM B JOG UP JOG DOWN AUTO/MANUAL VBATT RAISE VSWIT LOWER GROUND CONFIG

A Terex Company

LEFT SIDE

A B C C D O N N

System Four Grade and Slope Automation

SONIC TRACKER II

C O N N

A B C D E F G H J K L

COMM A COMM B VSWIT GROUND

Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation Troubleshooting System Checkout Grade Set-Up 1) Place the screed on the ground 2) Turn off engine. Ensure all switches are in the OFF position and the Brakes are Engaged. Observe the following:

3) Mount all System Four components on the machine and attach all connectors properly.

1) The Control Box should give a single audible beep.

4) Position the Sonic Tracker II 14 inches above the ground. Install the Temperature Bail on both Sonic Tracker II

2) The LCD Digital/Symbol Display should come on.

5) Start engine and let idle.

a.A digital number should appear.

6) Switch the Auto/ Manual/ Survey(Cal) switch to Manual on both control boxes.

System Four

AUTO M A N

This is a software revision number.

SURVEY (CAL)

b. A configuration number should appear next.

SystemFour 7) Place screed remote Mat Thickness Man/Setup/ Auto switches in SETUP on both sides of the screed. MAT THICKNESS

NOTICE: The display should always show “c009” as the configuration. If any thing other than this appears it is an indicator of a bad power cable or damaged junction box.

INCREASE

DECREASE

c. The digital display should momentarily display an “ERR”.

MAN SET-UP

System Four

STOP

8) On the right control box, switch the Elevation: Power / Off/ Slope: Power Switch to Elevation.

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Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation 1) Adjust the Grade Adjustment Knob on the Control Box in the direction indicated by the Grade Adjustment Arrows until the On Grade symbol illuminates.

NOTICE: If “ERR” is displayed continuously, the control box is not able to communicate with the Sonic Tracker II. Check the cable and connections. d. The Tracker symbol in the lower right corner of the LCD display should appear. System Four

OR

System Four

UNTIL=

==========

OR

Observe the following: 3) Grade Correction Display may show an UP, DOWN, ON GRADE or no light indicators. Also Grade Adjustment Arrows around the Grade Adjustment Knob should appear if the Correction Display is not showing ON GRADE.

1) The Sonic Tracker II and Control Box, Grade Correction Display should show On Grade.

4) Temperature Bail symbol should be displayed on the Sonic Tracker II display.

System Checkout Slope 1) Switch the Elevation: Power / Off / Slope: Power Switch to Slope.

TOPCON

T NOTICE: A transducer is failing if the Sonic Tracker II Bail indicator does nor appear while the bail is installed. 5) The Sonic Tracker II Transducer” should emit a ticking sound.

Observe the following: 1) The Control Box should give a single audible beep. 2) The LCD Digital/Symbol Display should come on.

TICK

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Operation & Maintenance Manual

A Terex Company

System Four Grade and Slope Automation a. A digital number should appear.

4) Grade Correction Display may show an UP, DOWN, ON GRADE or no light indicators. Also Grade Adjustment Arrows around the Grade Adjustment Knob should appear if the Correction Display is not showing ON GRADE.

System Four

This is a software revision number. b. A configuration number should appear next.

SystemFour 1) Turn the Adjustment Knob on the Control Box in the direction indicated by the Grade Adjustment Arrows until the On Grade symbol illuminates.

NOTICE: The display should always show “c009” as the configuration. If any thing other than this appears it is an indicator of a bad power cable or damaged junction box.

OR

c. The digital display should momentarily display an “ERR”.

UNTIL=

Observe the following: 1) The Control Box, Grade Correction Display should show On Grade.

System Four

NOTICE: If “ERR” is displayed continuously, the control box is not able to communicate with the Sonic Tracker II. Check the cable and connections. Switch the right control box OFF. Repeat System Checkout procedures for both grade and slope on the left side of the paver.

3) LCD Digital/Symbol Display should come on a. The (+ Slope) or (-Slope) should be on. A digital slope number should appear and the “%” symbol should appear. System Four

SystemFour

%

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Operating Checkout Grade Set-Up

OR

+

1) Place the screed on the ground 2) Turn off engine. Ensure all switches are in the OFF position and the Brakes are Engaged.

%

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Operation & Maintenance Manual

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System Four Grade and Slope Automation 3) Mount all System Four components on the machine and attach all connectors properly.

UNTIL=

OR

4) Position the Sonic Tracker II 14 inches above the ground. Install the Temperature Bail on both Sonic Tracker II

10) Switch the Auto/Manual/Survey(Cal) Switch to AUTO.

5) Start engine and let idle. 6) Switch the Auto/ Manual/ Survey(Cal) switch to Manual.

AUTO M A N

AUTO M A N

SURVEY (CAL)

SURVEY (CAL)

Observe the following: 1) The tow point should move up

7) Place screed remote Mat Thickness Man/Setup/ Auto switches in SETUP on both sides of the screed.

2) The Grade Correction Display should indicate On Grade when the cylinder stops moving.

MAT THICKNESS INCREASE

+ DECREASE

MAN

1) Switch the Auto/Manual/ Survey (Cal) Switch to Manual

SET-UP

STOP

AUTO

8) On the right control box, switch the Elevation: Power / Off/ Slope: Power Switch to Elevation.

M A N SURVEY (CAL)

2) Adjust the Grade Correction Display for a Down correction

9) Using the Grade Adjustment Knob, adjust the Grade Correction Display for an Up correction. 21048 (12/95)

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System Four Grade and Slope Automation

OR

AUTO

UNTIL=

M A N SURVEY (CAL)

3) Switch the Auto / Manual / Survey (Cal) Switch to Auto

6) Place screed remote Mat Thickness Man/Setup/ Auto switches in SETUP on both sides of the screed.

AUTO M A N

MAT THICKNESS

SURVEY (CAL)

INCREASE

Observe the following: DECREASE

1) The tow point should move down

MAN

2) The Grade Correction Display should indicate On Grade when the cylinder stops moving.

SET-UP

STOP

7) On the right control box, switch the Elevation: Power / Off/ Slope: Power Switch to Slope.

+

Operating Checkout Slope Set-Up 1) Place the screed on the ground 2) Turn off engine. Ensure all switches are in the OFF position and the Brakes are Engaged.

8) Using the Grade Adjustment Knob, adjust the Grade Correction Display for an Up correction.

3) Mount all System Four components on the machine and attach all connectors properly. 4) Start engine and let idle.

OR

UNTIL=

5) Switch the Auto/ Manual/ Survey(Cal) switch to Manual. 9) Switch the Auto/Manual/Survey(Cal) Switch to AUTO.

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Operation & Maintenance Manual

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System Four Grade and Slope Automation Observe the following: AUTO

1) The tow point should move down

M A N

2) The Grade Correction Display should indicate On Grade when the cylinder stops moving.

SURVEY (CAL)

Observe the following: 1) The tow point should move up

+

2) The Grade Correction Display should indicate On Grade when the cylinder stops moving.

System Performance Operational Check 1) Switch the Auto/ Manual/ Survey(Cal) switch to Manual on both control boxes.

+

AUTO M A N

1) Switch the Auto/Manual/ Survey (Cal) Switch to Manual

SURVEY (CAL)

AUTO M A N

2) Place screed remote Mat Thickness Man/Setup/ Auto switches in SETUP on both sides of the screed.

SURVEY (CAL)

2) Adjust the Grade Correction Display for a Down correction

OR

MAT THICKNESS INCREASE

UNTIL=

DECREASE

MAN

3) Switch the Auto / Manual / Survey (Cal) Switch to Auto

SET-UP

STOP AUTO

3) Switch the Elevation: Power / Off / Slope: Power Switch to Slope.

M A N SURVEY (CAL) 21048 (12/95)

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System Four Grade and Slope Automation OBSERVE THE FOLLOWING TOW POINT CYLINDER REACTION

4) Adjust the Grade Adjustment Knob on the Control Box in the direction indicated by the Grade Adjustment Arrows until the On Grade symbol illuminates.

OR

The tow point cylinder should move to the new position and stop. If the tow point cylinder does not move, the valve offset performance setting for that direction of cylinder movement is too slow and needs to be increased.

UNTIL=

If the tow point cylinder jumps a large distance and has to come back before stopping, the valve offset performance setting for that direction of cylinder movement is too Fast and needs to be decreased.

5) Switch the Auto/Manual/Survey(Cal) Switch to AUTO. AUTO M A N

7) Turn the Grade Adjustment Knob on the Control Box one click counterclockwise.

SURVEY (CAL)

6) Turn the Grade Adjustment Knob on the Control Box one click clockwise.

OBSERVE THE FOLLOWING TOW POINT CYLINDER REACTION

The tow point cylinder should move to the new position and stop. 21048 (12/95)

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System Four Grade and Slope Automation Symptom 2 - Control Box LCD Digital/Symbol Display reads “ERR”.

If the tow point cylinder does not move, the valve offset performance setting for that direction of cylinder movement is too slow and needs to be increased.

Probable Cause No communication with the sensor selected.

If the tow point cylinder jumps a large distance and has to come back before stopping, the valve offset performance setting for that direction of cylinder movement is too Fast and needs to be decreased.

1) Check that all cables are properly connected to System Four 2) Disconnect cables and inspect them for damage or contamination. Clean all connections with a commercial De-Greaser /Cleaner

IF NECESSARY READJUST VALVE OFFSET PERFORMANCE SETTING AND REPEAT SYSTEM PERFORMANCE OPERATIONAL CHECKS

3) If slope has been selected, check that slope had not been selected on the other Control Box 4) If elevation has been selected, swap the Sonic Tracker II and/or Cables with unit from opposite side to determine if symptom continues

Symptom Quick Reference 1) Control Box LCD Digital/Symbol Display does not come on

Symptom 3 - Cannot adjust to on grade when elevation control is selected.

2) Control Box LCD Digital/Symbol Display reads “Err”

Probable Cause Tracker is too close to control reference.

3) Cannot adjust to On Grade when Elevation control is selected

1) Check that the Sonic Tracker II is at least 14 inches away from the control reference

4) Tow point cylinder does not move Up or Down

2) Check for contamination on Sonic Tracker II. Transducer. Refer to Transducer and Filter replacement information in Maintenance and Parts

5) Tow point cylinder moves too fast or too slow 6) Cross slope being placed is not correct Troubleshooting Procedures Symptom 1 - Control Box LCD Digital/Symbol Display does not come on.

3) Swap the Tracker with the unit on the opposite side to determine if the symptom continues

Probable Cause

Symptom 4 - Tow point cylinder does not move up or down.

No power to Control Box. 1) Check that machine power is on and all switches for automatic control are in the proper position

Probable Cause Paver electrical switches are not in the proper position or hydraulics to the cylinder are not active.

2) Check that all cables are properly connected to System Four

1) Check that all paver electrical switches are in the correct position for automatic control.

3) Disconnect cables and inspect them for damage or contamination. Clean all connections with a commercial De-Greaser / Cleaner

2) Check hydraulic system is functioning properly.

4) Swap Control Box with the unit from the other side to see if the symptom continues. 21048 (12/95)

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System Four Grade and Slope Automation LH Electrical Automatic Screed Control

3) Check that the Auto / Manual / Survey (Cal) Switch is in Auto and that the Auto symbol is illuminated on the front panel

12 VDC

12 VDC - FORWARD ONLY

L.H. AUTOMATIC SCREED CONTROL

4) Disconnect cables and inspect them for damage or contamination. Clean all connections with a commercial De-Greaser /Cleaner

MAT THICKNESS 47 AUTO SET

46

152

L.H.AUTO ISOLATION RELAY 14

LAI

3

13

MAN 152

INC 155B 150

5) Swap the Control Box with the unit on the opposite side to determine if the symptom still exists

DEC 157B 157B

150 46

3 155B A B C D E F G H I J

Symptom 5 - Tow point cylinder moves too fast or too slow. Probable Cause System Performance Settings are not correct. 1) Adjust both the Gain, Deadband and Valve Offset Performance Settings to there recommended settings. Refer to “Accessing System Performance Settings”

3 46 155A 157A 155A 157A

3 4

155A

5

9

8

12

157A

1

155

B SOL.

3

157

A SOL.

3

10 PIN RECEPTACLE FOR AUTO CABLE

Tow Point Cylinder Does Not Raise or Lower in Manual Man/Setup/Auto switch in Manual.

2) Tow Point valve timing set faster or slower than 18 seconds.

Press Manual Override button on solenoid valve;

Symptom 6 - Cross slope being placed is not correct. Probable Cause

If Non-functional, refer to Hydraulic Troubleshooting.

Calibration on Slope Sensor is incorrect.

If Functional, proceed below. Check DIN connector on valve for light;

1) Calibrate the Slope Sensor as described in “Slope Calibration” in the Function section

If light is ON, check for 12VDC across solenoid coil (pin I to pin 2);

2) Check that the Transverse Beam is mounted properly with no looseness or damage.

If no voltage, check connection of DIN connector.

3) Re-check grade using a good reference such as a laser or level

If voltage, check and/or replace solenoid coil. If No Light;

4) Paver’s mat thickness controls have been used.

Check for 12VDC from 155 to 3 with switch in Increase, 157 to 3 with switch in Decrease. If no voltage, check 155B to 3 in Increase, 157B to 3 in Decrease. If voltage, check 152 to 3. Shouldn't have any voltage. Replace Man-Setup-Auto switch if voltage present. Replace Isolation Relay if no voltage.

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System Four Grade and Slope Automation If NO voltage, check 150 to 3;

RH Electrical Automatic Screed Control

If voltage, replace Increase-Decrease switch.

12VDC 12VDC - FORWARD ONLY

R.H. AUTOMATIC SCREED CONTROL

If NO voltage, check/replace Man/Setup/Auto switch.

47

46

MAT THICKNESS R.H. AUTO ISOLATION AUTO 13 14 SET 162 RAI MAN 162

If voltage, check wiring to valves.

RELAY 3

INC 165B 160 DEC 167B 167B

160

Topcon Control Does Not Raise or Lower Tow Point in Manual or Auto

46

165B A 3 46 B 165A C 167A D 167A E 165A

If Topcon control will NOT power up when Grade or Slope is selected; Check for 12VDC from 46 to 3 in Main Screed Box.

F

G H I J

If NO voltage, check wiring from Tractor. If voltage, check for 12VDC from pin F to pin K at Controller power cable.

3 4

1

165A 167A

8

12

5

9

165

B SOL.

3

167

A SOL.

3

10 PIN RECEPTACLE FOR AUTO CABLE

If NO voltage, check wiring from Main Screed Box.

Tow Point Cylinder Does Not Raise or Lower in Manual

If voltage, proceed to Topcon Troubleshooting.

Man/Setup/Auto switch in Manual.

If Topcon control powers up when Grade or Slope is selected but valves will not operate;

Press Manual Override button on solenoid valve; If Non-functional, refer to Hydraulic Troubleshooting.

Check for 12VDC from 155A for UP, 157A for DOWN;

If Functional, proceed below.

If NO voltage, proceed to Topcon Troubleshooting.

Check DIN connector on valve for light; If light is ON, check for 12VDC across solenoid coil (pin I to pin 2);

If voltage, check for 12VDC from 155 for UP, 157 for DOWN; If voltage, check wiring to valves.

If no voltage, check connection of DIN connector.

If NO voltage, check 152 to 3.

If voltage, check and/or replace solenoid coil.

If voltage, check Isolation Relay by switching with RH Relay. Replace if defective.

If No Light; Check for 12VDC from 165 to 3 with switch in Increase, 167 to 3 with switch in Decrease.

If NO voltage, check/replace Man/Setup/Auto switch.

If no voltage, check 165B to 3 in Increase, 167B to 3 in Decrease. If voltage, check 162 to 3. Should not have any voltage. Replace Man/Setup/Auto switch if voltage present. Replace Isolation Relay if no voltage.

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System Four Grade and Slope Automation Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point functions and etc.) If other functions work, this indicates the problem is only in the effected function and the general auxiliary system is working.

If NO voltage, check 160 to 3; If voltage, replace Increase-Decrease switch. If NO voltage, check/replace Man/Setup/Auto switch. If voltage, check wiring to valves.

If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for lose fittings, damaged hose, or obstructions.

Topcon Control Does Not Raise or Lower Tow Point in Manual or Auto If Topcon control will NOT power up when Grade or Slope is selected; Check for 12VDC from 46 to 3 in Main Screed Box. If NO voltage, check wiring from Tractor.

Tow Point Will Not Increase

If voltage, check for 12VDC from pin F to pin K at Controller power cable.

Engine at FULL THROTTLE. Tow point Increase/Decrease switch to the INCREASE position.

If NO voltage, check wiring from Main Screed Box.

Check for DIN connector light, if no light refer to electrical troubleshooting.

If voltage, proceed to Topcon Troubleshooting. If Topcon control powers up when Grade or Slope is selected but valves will not operate;

If light is ON: 1) Refer to electrical for testing ground connection.

Check for 12VDC from 165A for UP, 167A for DOWN;

2) Press MANUAL OVERRIDE button on solenoid valve.

If NO voltage, proceed to Topcon Troubleshooting.

If tow point cylinder increases, defective solenoid.

If voltage, check for 12VDC from 165 for UP, 167 for DOWN;

If tow point cylinder does not increase: 1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and manifold block. if full pressure reading but no cylinder movement, plugged or defective holding valve.

If voltage, check wiring to valves. If NO voltage, check 162 to 3. If voltage, check Isolation Relay by switching with LH Relay. Replace if defective.

2) Extend cylinder all the way, disconnect the hose going to the ROD END of the tow point cylinder. Carefully push the increase/decrease switch to DECREASE. If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing.

If NO voltage, check/replace Man/Setup/Auto switch. Tow Point Hydraulic Auxiliary System Check hydraulic fluid level.

If no fluid, defective solenoid.

Engine at FULL THROTTLE.

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Operation & Maintenance Manual

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System Four Grade and Slope Automation Tow Point Cylinder Timing Refers to the length of time it takes to extend or retract the tow point cylinder. A dual hydraulic throttle valve is adjusted so the extend and retract stroke of the cylinder occurs in 18 seconds.

Tow Point Will Not Decrease Engine at FULL THROTTLE. Tow point increase/decrease switch to the DECREASE position. Check for DIN connector light, if no light refer to electrical troubleshooting.

Checking Cylinder Timing 1) Acquire two pieces of pipe 2” OD or greater and 1’ in length.

If light is ON: 1) Refer to electrical for testing ground connection.

2) Place the pieces of pipe under each end of the screed.

2) Press MANUAL OVERRIDE button on solenoid valve. If tow point cylinder decreases, defective solenoid. If tow point cylinder does not decrease: 1) Install a 3000 psi gauge in-line, between hose going to base end of cylinder and manifold block. If full pressure reading but no cylinder movement, plugged or defective holding valve.

Place pipe on each side of screed and in center of screed

3) Center both tow point cylinders at 6 on the number scale.

2) Retract cylinder all the way, disconnect the hose going to the BASE END of the tow point cylinder. Carefully push the increase/decrease switch to INCREASE, If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing.

Center

If no fluid, defective solenoid. Tow Point Cylinder Drifts Up or Down

4) Set engine at Full Throttle.

Engine at FULL THROTTLE

5) On the right side retract the tow point cylinder fully.

Check DIN connectors for lights, If any light on, electrical system is telling the cylinder to move. If no lights are flashing on, proceed with checks.

Retracted Fully

Extend cylinder all the way, disconnect the hose going to the ROD END of the tow point cylinder. Carefully push the increase/decrease switch to DECREASE, if fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing.

6) Extend cylinder: Using a stop watch note the amount of time it takes to fully extend the tow point cylinder.

If no fluid, defective holding valve. 21048 (12/95)

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System Four Grade and Slope Automation Tow Point Timing Adjustment TO

All checks and adjustments should be performed with Engine at FULL THROTTLE and machine at operating temperature.

18 Seconds

To adjust the tow point timing locate the perspective dual throttle valve.

7) On the right side extend the tow point cylinder fully. Extend Fully

RH Front Bulkhead Valves

3. 8) Retract cylinder: Using a stop watch note the amount of time it takes to fully extend the tow point cylinder.

2.

1.

TO

LH Front Bulkhead Valves

18 Seconds

9) Center right tow point cylinders at 6 on the number scale.

3.

Center

2. 10) Repeat Steps 4 through 9 on the left side.

1.

If either the up or down stroke time was anything other than 18 seconds, adjust Tow Point Timing according to “Tow Point Timing Adjustment” in this chapter.

1) Solenoid Valve: Used to direct hydraulic fluid to either the rod or base ports of the tow point cylinder. 2) Dual Throttle Valve: Used to set cylinder travel speed for both directions to 18 seconds.

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Operation & Maintenance Manual

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System Four Grade and Slope Automation 3) Holding Valve: Used to hydraulically lock the tow point cylinders.

To adjust the perspective up or down stroke time. 1) Loosen Jam Nut.

The Dual Throttle Valve adjustment points are as follows:

2) Using a Allen Wrench (Hex Wrench) turn adjuster a slight amount.

Adjusts Timing for UP Stroke

Adjustor Jam Nut Clockwise rotation DECREASES cylinder speed.

Adjusts Timing for DOWN Stroke

Adjustor

Jam Nut

Counterclockwise rotation INCREASES cylinder speed.

3) Tighten Jam Nut. 4) Recheck tow point timing according to procedures listed in :Checking Tow Point Timing” and readjust if necessary.

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System Four Grade and Slope Automation

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54

Topcon System 5 & Smoothtrac

Topcon Corporation

System 5 & Smoothtrac® Operator's Manual 7010-0341 Rev. D

(P/N 499992526004) 23021 (11/02)

© 2002 TOPCON Positioning Systems, Inc. All rights reserved. No part of this manual may be reporduced in any form or by any means without prior written permission from:

TOPCON Positioning Systems, Inc.

Warranty

Warranty TOPCON Limited Warranty Electronic and Mechanical Components TOPCON warrants that the electronic components manufactured by TOPCON shall be free of defects in materials and workmanship for a period of one year from the original date of shipment to the dealer. TOPCON warrants that all valves, hoses, cables and mechanical parts manufactured by TOPCON shall be free of defects in materials and workmanship for a period of 90 days from the date of installation.

Return and Repair During the respective warranty periods, any of the above items found defective may be shipped to TOPCON for repair. TOPCON will promptly repair the defective item at no charge, and ship it back to you. Calibration of components, labor and travel expenses incurred for in-field removal and replacement of components are not covered under this warranty policy. Damage to components due to negligence, abuse or improper use is NOT covered under this warranty.

Warranty Disclaimer The above warranties are in lieu of all other warranties, whether expressed or implied, including all warranties or merchantability, or fitness for a particular purpose. In no event will Topcon Positioning Systems, Inc. or its Representative be liable for lost profits or other consequential damages arising from the purchase or use of TOPCON’s System FiveTM Paver Operator's Manual

W-1

Warranty

components or any performance hereunder or any claims of negligence, even if TOPCON has been advised of the possibility of such damages. Service assistance can be provided by contacting your local TOPCON dealer or by calling the Corporate Service Center. Travel charges will be applied for any on-site service whether warranty or non-warranty in nature. Phone: (866) 4-TOPCON - (866-486-7866) 8 a.m. to 5 p.m. Pacific Time Monday through Friday FAX: (925) 460-1329

W-2

System FiveTM Paver Operator's Manual

Foreword

Foreword TOPCON Positioning Systems, Inc.TM produces productivity enhancement tools engineered and manufactured by professionals from the construction industry. The efficient design and advanced technology of TOPCON Positioning SystemsTM System FiveTM allows you to increase production, effectively control materials, and reduce time spent setting and checking grade. This manual has been developed to provide the paver operator with information necessary to operate and maintain TOPCON System FiveTM. Proper service and use is important to the reliable operation of the equipment. The procedures described herein are effective methods for performing service and operation of this system. The sections provided in this manual include information necessary for the correct operation care and troubleshooting of your TOPCON System FiveTM. Also contained in this manual is a selection of WARNINGS, CAUTIONS, and NOTICES you should become familiar with in order to safely operate the system. Each symbol represents a particular level of danger:

WARNING

WARNING

Represents a procedure or operation that, if not strictly followed, can cause serious damage to the equipment, and/or serious injury or death to the person performing the operation. System FiveTM Paver Operator's Manual

F-1

Foreword

CAUTION

CAUTION

Represents a procedure or operation that, if not followed correctly, can result in serious damage to the equipment or personal injury. NOTICE

NOTICE

Represents a procedure that, if not performed correctly, can adversely effect the performance of the equipment. Please study this manual carefully. The benefits this product provides can be greatly influenced by your applications knowledge. All information, illustrations, and applications contained herein are based on the latest available information at the time of publication. TOPCON reserves the right to make product changes at any time without notice. Comments, suggestions, and questions about TOPCON products are welcomed. Contact your local TOPCON representative or a representative at our corporate facility. TOPCON POSITIONING SYSTEM, Inc. 5758 W. Las Positas Blvd. Pleasanton, CA 94588 925 / 460 1300 925 / 460 1315 FAX

F-2

System FiveTM Paver Operator's Manual

Table of Contents

Table of Contents Warranty ............................................................... W-1 Limited Warranty ............................................................. W-1 Electronic and Mechanical Components ................... W-1 Return and Repair ..................................................... W-1 Warranty Disclaimer .................................................. W-1 Foreword ................................................................ F-1 Table of Contents .............................................. TOC-1 Safety Information .................................................. S-1 General Precautions ......................................................... S-1 Chapter 1: System Overview .................................. 1-1 Paver Illustration ................................................................ 1-2 Control Box ........................................................................ 1-3 LCD ....................................................................... 2-3 Light Sensor for LCD ................................................... 2-3 Power Switch .............................................................. 2-3 Grade Adjustment Knob .............................................. 2-4 Grade Adjustment Arrows ........................................... 2-5 Grade Adjustment LED ............................................... 2-6 Set/Menu Button ......................................................... 2-7 Slope/Elevation Button ................................................ 2-8 Survey/Indicate Button ................................................ 2-9 Auto/Manual Button ................................................... 2-10 Jog Switch ................................................................. 2-11 Sonic Tracker IITM ........................................................................................................ 1-4 Slope Sensor ..................................................................... 1-5 Smoothtrac® Sonic Averaging System (SAS) ................... 1-6 Laser Tracker & Trackerjack ............................................. 1-7 Carrying Case .................................................................... 1-8

System FiveTM Paver Operator's Manual

TOC-1

Table of Contents Chapter 2: Operation .............................................. 2-1 Control Box ........................................................................ 2-1 Control Box Frt Pnl Switches and Controls ................. 2-2 Other Control Box Components ................................ 2-12 Sonic Tracker II ......................................................... 2-13 Working Window ................................................. 2-15 Slope Control ............................................................ 2-27 Performance Menu ................................................. 3-1 Control Box Memory .......................................................... 3-1 Accessing Menu Settings ..................................... 3-1 Gain (Elevation) ............................................. 3-5 Gain (Slope Control) ...................................... 3-7 Valve Offset .................................................... 3-9 Averaging ..................................................... 3-12 Deadband Elevation ..................................... 3-14 Deadband Slope .......................................... 3-16 Beeper Alarm ............................................... 3-18 Unit ............................................................... 3-19 Test .............................................................. 3-21 Principles of Paving ................................................ 4-1 Paver Components ............................................................ 4-1 How a Screed Works ......................................................... 4-2 Tow Point Force ................................................................ 4-6 Truck Exchange .......................................................... 4-7 "M" Head of Material .......................................................... 4-8 "R" Reaction of Material Under Screed ........................... 4-10 Mix Characteristics .......................................................... 4-11 Gradation .................................................................. 4-11 Mix Temperature ............................................................. 4-13 "W" Weight of Screed ...................................................... 4-14 Quality of Base Being Paved ........................................... 4-15 Rolling Techniques .......................................................... 4-16 Controlling Mat Quality .................................................... 4-16

TOC-2

System FiveTM Paver Operator's Manual

Table of Contents Getting Ready to Pave ........................................... 5-1 Machine Setup ................................................................... 5-2 Sonic Tracker Setup .......................................................... 5-5 Control Box Setup - Elevation ........................................... 5-6 Control Box Setup - Cross Slope ..................................... 5-11 Tracker Placement ................................................. 6-1 Stringline ................................................................ 7-1 Setting Surface Stringline .................................................. 7-1 Setting Elevated Stringline ................................................ 7-5 Making a Grade Verification Lath .............................. 7-13 Verifying Grade ......................................................... 7-14 Smoothtrac® (SAS) Set Up ..................................... 8-1 Positioning the SAS ........................................................... 8-5 Placement of Sonic Averaging System ............................. 8-9 Applications ............................................................ 9-1 Paving City Streets with Sonics ......................................... 9-1 Paving City Streets with Cross Slope ................................ 8-9 Paving Streets Through Intersections ............................... 9-7 Method 1 ..................................................................... 9-7 Method 2 ................................................................... 9-10 Paving Intersections with Cross Slope ............................ 9-11 Maitenance ........................................................... 10-1 Preventative Maintenance & Daily Care .......................... 10-1 Transducer Cleaning ....................................................... 10-3 Transducer Replacement Procedure ............................... 10-4 Troubleshooting ................................................... 11-1 Control Box Symptoms .................................................... 11-1 Tracker Symptoms ........................................................ 11-13 Slope Sensor Symptoms ............................................... 11-17 SAS Symptoms ............................................................. 11-21 Appendix ............................................................................ A-1

System FiveTM Paver Operator's Manual

TOC-3

Table of Contents

Notes

TOC-4

System FiveTM Paver Operator's Manual

Safety Information

Safety Information It is your responsibility to be completely familiar with the cautions described in this System FiveTM Manual. These messages advise against the use of specific methods or procedures which can result in personal injury, damage to the equipment, or unsafe operating conditions. Remember, most accidents are caused by failure to observe basic safety precautions.

General Precautions 1.

Read and become familiar with the paver manufacturer’s operations manual, including safety information before installing or using your TOPCON System FiveTM.

2.

Use extreme caution on the jobsite. Working around heavy construction equipment can be dangerous.

3.

System Five is externally mounted on the paving machine. DO NOT install the system while the paver is running.

4.

DO NOT allow any System FiveTM component to limit the visibility of the operator or protrude into traffic.

5.

Use Ty-Wraps supplied with System FiveTM to keep hoses and wires secured and away from possible wear or pinch points.

System FiveTM Paver Operator's Manual

S-1

Safety Information

6.

Use eye protection when welding, cutting or grinding is being done on the machine.

7.

Protect yourself at all times and wear protective clothing when working on or near hydraulic lines. Hydraulic lines can be under extreme pressure even when the machine is turned off.

WARNING

WARNING

Relieve all pressure in the hydraulic lines before disconnecting or removing any lines, fittings or related components. If injury does occur, seek medical assistance immediately. 8.

CAUTION

Avoid direct exposure to your eyes when using laser control.

CAUTION

DO NOT stare into the laser beam or view the beam directly with optical equipment. 9.

Use appropriate welding precautions and practices when welding. After welding, all affected areas should be painted with a rust inhibitor.

NOTICE

NOTICE

Disconnect all TOPCON system electrical cables prior to welding on the machine. S-2

System FiveTM Paver Operator's Manual

Safety Information

WARNING

WARNING

Do not weld near hydraulic lines or on any equipment when in operation. NOTICE

NOTICE

All mounting bracket welds must be secure and strong to prevent the sensor equipment from vibrating excessively or from becoming detached at the weld during operation. NOTICE

NOTICE

Keep the Carrying Case dry at all times. DO NOT allow moisture to get inside the case. Moisture trapped in the case can adversely affect components. If moisture does enter the Carrying Case, leave it open and allow it to thoroughly dry before storing any components. 10. To prevent vandalism or theft, do not leave the removable TOPCON components (Control Boxes, Sonic Tracker IIsTM and cables) on the machine at night. Remove the components each evening and store appropriately in the Carrying Case.

S-3

System FiveTM Paver Operator's Manual

Safety Information

Notes

S-4

System FiveTM Paver Operator's Manual

Chapter 1: System Overview

System Overview System FiveTM is a complete, non-contacting control system which combines both elevation control and slope control into a simple, easy to use package. A standard system includes two (2) Control Boxes, two (2) Sonic Tracker IITM's and a single (1) Slope Sensor. The Control Box on the right side of the machine controls the right side for either elevation or slope. Likewise, the left Control Box controls the left side for either elevation or slope. The primary function of System FiveTM is to provide screed control so that the paving material is placed into position at the correct elevation and slope.

1-1 Figure 1.01 System FiveTM Paver Operator's Manual

Chapter 1: System Overview

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System FiveTM Paver Operator's Manual

Chapter 1: System Overview

Control Box The Control Box is the operator’s interface to System FiveTM. The Control Box receives signals from the sensors, (Sonic Tracker IITM, Laser Tracker and/or Slope Sensor), and uses these signals to determine if grade or slope corrections are necessary. If a change in grade or slope is required, the Control Box sends a signal to the valve controlling the tow point cylinder on the appropriate side of the machine to raise or lower, thus maintaining correct mat thickness. The Control Box easily attaches to its mounting bracket with one clamp, and at the end of the day should be removed for storage. The Control Box connects to the Sonic Tracker IITM, the Slope Sensor, and to the paver through electrical cables.

1-3 Figure 1.03

System FiveTM Paver Operator's Manual

Chapter 1: System Overview

Sonic Tracker IITM The Sonic Tracker IITM measures and controls the elevations of the screed. A transducer, located in the bottom of the Sonic Tracker IITM, generates sound pulses like a speaker and listens for returned echoes like a microphone. The Tracker measures the distance, and controls grade from a physical grade reference, such as a curb, stringline, or existing road surface. A bail is used to compensate for rapid air temperature changes. In paving applications a bail should always be used. The Sonic Tracker IITM attaches to the system through one quick connect cable and attaches to the machine with a single bolt. At the end of the day, Sonic Tracker IITM should be removed for proper storage in the carrying case.

1-4 Figure 1.04 System FiveTM Paver Operator's Manual

Chapter 1: System Overview

Slope Sensor The Slope Sensor is a precision electronic sensor which functions much like a precision carpenter's level. The Slope Sensor reads the inclination (tilt) of the screed and sends the signal to the Control Box. The Slope Sensor will measure slopes from +20% to -20%. The Slope Sensor is a sealed unit and contains no adjustments. It is the only component of System FiveTM which may be selected to control either side of the paver. It is connected to each Control Box through an electrical cable. The Slope Sensor is a sealed component and once attached to the paver should not be removed.

Figure 1.05

System FiveTM Paver Operator's Manual

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Chapter 1: System Overview

Smoothtrac® Sonic Averaging System (SAS) The Smoothtrac is an elevation control system that combines multiple Sonic Tracker II's together to calculate an average of the physical reference. Each tracker sends its distance measurement to the Control Box which then averages all of those measurements and sends a correction signal to the tow point cylinder. The Smoothtrac replaces the mechanical ski that drags on the ground. The Smoothtrac connects to the Control Box through the tracker cable.

1-6

Figure 1.06

System FiveTM Paver Operator's Manual

Chapter 1: System Overview

Laser Tracker & Trackerjack The Laser Tracker is an elevation control sensor. It measures and controls the elevation of the screed. It works by receiving a signal from a rotating laser and sending a signal to the Control Box. The Trackerjack attaches to the laser receiver and then mounts onto a vibration pole. Use the same cable from the Sonic Tracker IITM to power up the Laser Tracker/Trackerjack System. The Laser Trackerjack should be removed at the end of each day and stored in its carrying case. Figure 1.07

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Chapter 1: System Overview

Carrying Case A Carrying Case is provided with each System FiveTM. The Carrying Case is lined and includes pre-cut sections for each Sonic Tracker IITM and the Control Boxes. A cut-out section is also provided for storing coil cords. At the end of the day, always wipe down each of the components and place them and the coil cords in the appropriate sections for storage. This will ensure the continued integrity of these components and will protect them from vandalism or theft.

Figure 1.08

NOTICE 1-8

Keep the Carrying Case dry and store in a dry location. Never let the interior of the Carrying Case become wet. If the case does become wet, remove the components and dry it out. System FiveTM Paver Operator's Manual

Chapter 2: Operation

Operation NOTICE When operating in rainy weather or in wet conditions, the Control Box, Sonic Tracker IITM, and cables must be thoroughly dried BEFORE placing them in the Carrying Case at the end of the day. Any moisture in the Carrying Case will cause condensation on the inside of the components which may severely affect accurate operation during the next paving operation.

Control Box The Control Box is the main operator control interface for System FiveTM. The Control Box receives signals from the sensors and uses these signals to determine if a grade or slope correction is necessary. If a correction is necessary the Control Box sends a signal to the valve controlling the tow point cylinder on the appropriate side of the paver to raise or lower, thus maintaining correct mat thickness.

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Chapter 2: Operation

Control Box Front Panel Switches, Buttons and Controls The operator can control and monitor the slope and thickness of the mat using the buttons and displays located on the front panel of the Control Box. The function of each is as follows:

Figure 2.0

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Chapter 2: Operation

1 The LCD (Liquid Crystal Display) The LCD allows the operator to view text and graphic symbols that represent elevation or slope settings that System FiveTM is currently maintaining for the paver.

Figure 2.01

2 Light Sensor for LED Display Automatically adjusts the brightness of the LED display for better visability. 3 Power Switch The Power Switch for System FiveTM. •

Press "|" on the switch to turn the Box on.

•

Press "O" on the switch to turn the Box off.

Figure 2.02

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Chapter 2: Operation

4 Grade Adjustment Knob This knob is used to make measured adjustments to the Cross Slope or Elevation settings and allows the operator to cycle through the menu options. •

Knob adjusts the grade height for when Elevation Control is selected.

Figure 2.03a

•

Knob adjusts the percentage of slope when Cross Slope Control is selected.

2-4 Figure 2.03b System FiveTM Paver Operator's Manual

Chapter 2: Operation

Grade Adjustment Direction Arrows These red arrows light up around the Grade Adjustment Knob to indicate the direction the knob should be rotated to reach On Grade. A

Rotate the knob counterclockwise to reach grade.

B

Rotate the knob clock wise to reach grade.

Figure 2.03c

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System FiveTM Paver Operator's Manual

Chapter 2: Operation

6 Set/Menu Button The Set/Menu button has two functions. •

Set Mode Set is used to change the reference number viewed on the display to a desired value. Press and hold the Set/Menu button and dial in desired value using the Grade Adjustment Knob. Both the Grade Correction Indictor Lights and the Double Arrows will be lit. Release the Set/Menu Button and the value will be saved. NOTICE

Using Set will not change the existing mat thickness, it only changes the reference number viewed on the display. •

Menu Mode (See Accessing System FiveTM Performance Settings)

2-7 Figure 2.05 System FiveTM Paver Operator's Manual

Chapter 2: Operation

7 Slope/Elevation Button The Slope/Elevation button is used to select System FiveTM for slope or elevation control. •

Slope Mode Press the button and the yellow LED next to the Cross Slope Symbol will illuminate.

•

Elevation Mode Press the button again and green LED next to the Elevation Symbol will illuminate.

Figure 2.06

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Chapter 2: Operation

8 Survey/Indicate Button •

Survey Survey is used to quickly "Null Out", or set the sensor to On-grade. Push button for 1 second until box beeps and green On-Grade Correction Display bar is illuminated.

•

Indicate Indicate Mode allows the operator to continuously monitor the grade or slope setting on the LCD. Continue pressing on the button until there is a second beep. "IND" will be shown in the LCD display. There will be no Grade lights. To exit out of Indicate Mode push either the Survey button or the Auto Button. NOTICE

By entering Indicate Function, System FiveTM will be taken out of Automatic Mode.

2-9 Figure 2.07 System FiveTM Paver Operator's Manual

Chapter 2: Operation

9 Auto/Manual Button •

Automatic Mode The tow point cylinders are automatically adjusted up or down to maintain proper grade. Press the red button. The red LED will light up showing that the Control Box is in Auto Mode.

•

Manual Mode System FiveTM will display grade corrections but the tow point cylinders will not be adjusted. Press in the Red Button. The red LED will NOT be lit, showing that the Box is in Manual Mode.

Figure 2.08

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10

Jog Switch Manually moves the tow point up or down. The Jog Switch is always active when the Control Box is turned on. • •

To raise tow arm cylinder, push switch up. To lower tow arm cylinder, push switch down.

Figure 2.09

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Chapter 2: Operation

Other Control Box Components

Figure 2.10

1 Mounting Knob Secures Control Box to its mounting bracket. The bracket has a jaw that matches up with the jaw located on the side of the Box. 2 Serial Number Plate Contains System FiveTM part and serial number.

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3 Audible Beeper When the power is turned on, or calibration selections are made, the beeper will sound. The beeper may be turned Off or On for certain functions by using the Beeper Alarm Mode (see Accessing System FiveTM Performance Settings section in this booklet). System FiveTM Paver Operator's Manual

Chapter 2: Operation

Sonic Tracker II The Sonic Tracker IITM measures and controls the elevation of the screed. A transducer, located in the bottom of the Tracker, generates sound pulses like a speaker and listens for returned echoes like a microphone. The Tracker measures the distance, and controls grade from any physical grade reference, such as a curb, stringline, or existing road surface.

Figure 2.11a

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Chapter 2: Operation

The Sonic Tracker IITM measures the distance to a physical reference by sending out sound pulses 39 times per second. As soon as the Tracker sends out a sound wave it starts a stop watch. The sound waves go down, bounce off of any physical reference, and are reflected back to the Tracker. The Tracker measures the time it takes for the sound wave to return to the Tracker. Knowing the speed of sound, the Tracker accurately calculates the exact distance to the grade reference. The Tracker can use any physical grade reference, such as a stringline, curb, or existing surface.

2-14

Figure 2.11b

System FiveTM Paver Operator's Manual

Chapter 2: Operation

•

Working Window Since the Sonic Tracker IITM is mounted to the tow arm or screed extension, as they raise or lower, the tracker measures exactly how far above or below the desired grade reference it is. Built into the Tracker is an operational zone, or Working Window, 2.4 inches above and below the grade reference. The grade lights on the Sonic Tracker and Control Box continuously display this grade information to the screed operator.

2-15 Figure 2.12a

System FiveTM Paver Operator's Manual

Chapter 2: Operation

On the paver the Sonic Tracker II will be positioned above the grade reference. Its job is to maintain the exact distance from the tracker to the reference, keeping the Tracker On Grade. If the Tracker is On Grade, the mat being laid will be at the desired depth.

Figure 2.12b

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Chapter 2: Operation

If the screed and the Tracker IITM start to raise, the watch will be stopped at a longer time. The Tracker and Control Box will indicate a down correction arrow, and lower hydraulic valve corrections will be applied to bring the Tracker back to On Grade.

Figure 2.12c

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Chapter 2: Operation

If the screed and Tracker IITM are lowered the watch will be stopped at a shorter time. The Tracker and Control Box will indicate a raise correction arrow, and raise hydraulic valve corrections will be applied to bring the Tracker back to On Grade.

Figure 2.12d

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Chapter 2: Operation

If the Tracker IITM is side shifted off a stringline, the sound waves reflect off the ground and the Tracker's stopwatch will indicate a long time for the sound waves to return. The Tracker is out of the Working Window, and no On Grade correction signals will be applied.

Figure 2.12e

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Chapter 2: Operation

If the Tracker sees an obstruction closer than the reference signal, such as a grade pin, the sound waves do not take as long to come back and the stop watch is stopped much sooner. The Tracker is out of the Working Window, and no On Grade correction signals will be applied.

Figure 2.12f

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Chapter 2: Operation

Temperature will change the speed of sound. The tracker has a built in temperature sensor for applications with gradual temperature changes such as on graders or dozers. In paving applications you can get a more dramatic and rapid change in air temperature. To compensate for these variations a temperature bail is positioned 9 inches below the tracker. When the sound wave is emitted, the tracker records the time to the bail and continues to listen for the grade reference. If a temperature variation occurs, such as heat off a freshly paved mat, a difference in time to the temperature bail is recorded. The correction for the speed of sound is then applied to the grade reference signal, preventing a change in mat depth. The tracker corrects for temperature variations with every sound wave, 39 times per second.

2-21 Figure 2.12g System FiveTM Paver Operator's Manual

Chapter 2: Operation

In the upper right hand corner of the Sonic Tracker IITM faceplate is a small symbol used to represent the use of the temperature bail. The LED symbol will automatically illuminate when the bail is connected to the tracker. The tracker is casted with holes on each side for the bail to snap and lock into place.

2-22 Figure 2.12h System FiveTM Paver Operator's Manual

Chapter 2: Operation

When setting up the Tracker over a grade reference, the size of the Sonic Cone or the "footprint" needs to be considered. As an example, at about 2 feet from the tracker, you will have a footprint or cone of about 6 inches. As the Tracker is positioned closer to the grade reference the working footprint decreases in size. As the Tracker is moving farther away from the grade reference the sonic footprint or cone will increase in size.

Figure 2.12i

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Chapter 2: Operation

For Laser Control a laser transmitter is used to produce a plane of light which becomes the grade control reference for the job site. The laser receiver will control the screed to lay a mat parallel to the laser beam reference. When the laser beam is in the center of the receiver, it indicates an On-Grade signal.

Figure 2.12j

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Chapter 2: Operation

As the screed is raised, the beam of light hits the Laser Receiver below the center and a lower signal is indicated.

Figure 2.12k

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Chapter 2: Operation

As screed is lowered the beam of light hits the Laser Receiver above the center a raise signal is indicated.

Figure 2.12l

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Chapter 2: Operation

•

Slope Control System Five uses a slope sensor mounted to the transducer beam on the paver to measure and control the slope of the mat being laid. The sensor contains an electronic level vial, that acts as a "precision carpenter's level". Slope control with this electric level vial is very accurate and repeatable.

Figure 2.12m

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Chapter 2: Operation

If the required slope changes, the screed man dials the new slope in the System Five Box. The tow point cylinder on the slope side will raise or lower until the slope sensor measures the new slope.

Figure 2.12n

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Chapter 3: Performance Menu

Performance Menu Control Box Memory The Control Box automatically stores all operating information when it is turned off. NOTICE If power is interrupted to the Control Box within 2 seconds after making an adjustment, the new setting will not have had time to be stored and the settings will revert to the previous (or original) settings. Accessing System Five TM Performance Menu Settings System FiveTM Performance Menu Settings are a series of features that allow System FiveTM to be modified for operator ease-of-use reasons, or performance enhancement reasons. Performance Menu Settings Chart

3-1 Figure 3.0 System FiveTM Paver Operator's Manual

Chapter 3: Performance Menu

NOTICE Some of the Menu selections may not be available for the operator to select or change. Please contact dealer/distributor with any questions. NOTICE The factory settings are preset values that will run most pavers. If your machine does not perform properly within those preset values, then adjust the setting accordingly until you have satisfactory machine performance. 1. Turn power off. While holding down the Set/ Menu button turn the box back on. The Auto LED light and Grade Adjustment Direction Arrows will flash.

Figure 3.01a

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Chapter 3: Performance Menu

2. Rotate the Grade Adjustment Knob to scroll through the Performance Menu selections located on the LCD.

Figure 3.01b

3. Select a menu item by pressing the Auto button.

Figure 3.01c

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Chapter 3: Performance Menu

4. Turn the Grade Adjustment Knob to view the options available for the Menu selection.

Figure 3.01d

5. Press the Auto button again to store value.

Figure 3.01e

6. To access other Menu settings just turn the Grade Adjustment Knob. To exit Performance Menu press the Set/Menu button.

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Chapter 3: Performance Menu

Gain (Elevation) This setting determines the speed at which System FiveTM allows the Tow Point Cylinders to adjust to a change in elevation. For faster hydraulic response, increase the gain value. For slower hydraulic response, decrease the gain value. The objective is to set the gain so the screed reacts to the change in grade quickly but without "overshooting" the new elevation. • •

Gain Elevation Value Range: 1-100 Factory Preset: 25 NOTICE

Before setting the Gain, make sure the machine's hydraulic flow controls valves are adjusted for proper cylinder speed according to the manufacturer's recommendations. Typical cylinder speed is 15-20 seconds for full up or down cylinder travel. 1. Press the Auto button to select Gain (Elevation).

Figure 3.02a

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Chapter 3: Performance Menu

2. Turn the Grade Adjustment Knob to select the desired value - typically 25 for most paving applications.

Figure 3.02b

3. Press the Auto button again to store value. 4. Rotate the Grade Adjustment Knob to access another choice in the Performance Menu or press the Menu button to exit.

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Chapter 3: Performance Menu

Gain (Slope Control) This setting determines the speed at which System FiveTM allows the Tow Point Cylinders to adjust to a change in slope. For faster hydraulic response, increase the gain value. For slower hydraulic response, decrease the gain value. The objective is to set the gain so the screed reacts to the change in grade quickly but without "overshooting" OnGrade. Slope gain should not be set at a higher value than the elevation gain on the other side of the paver. • •

Gain Elevation Value Range: 1-100 Factory Preset: 25 NOTICE

Before setting the Gain, make sure the machine's hydraulic flow controls valves are adjusted for proper cylinder speed according to the manufacturer's recommendations. Typical cylinder speed is 15-20 seconds for full up or down cylinder travel. 1. Press the Auto button to select Gain (Slope Control).

Figure 3.03a

System FiveTM Paver Operator's Manual

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Chapter 3: Performance Menu

2. Turn the Grade Adjustment Knob to select the desired value - typically 20% to 25%.

Figure 3.03b

3. Press the Auto button again to store the value. 4. Rotate the Grade Adjustment Knob to access another choice in the Performance Menu or press the Menu button to exit. NOTICE Do not set slope gain at a higher value than the elevation gain on the other side of the paver. A higher value may cause the slope to be over reactive.

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Chapter 3: Performance Menu

Valve Offset The valve offset is the minimum amount of electrical signals sent to the valve which causes the hydraulic cylinder to move. If the valve offset is too small, the sensor will not reach On-Grade. Likewise, if the valve offset value is too large, the sensor will move too much and overshoot On-Grade. Valve offsets should be set before adjusting elevation and slope gains and averaging. •

•

Valve Offset Value Range: 1-700 Solenoid: 135 Proportional: 350 Factory Preset: 135 NOTICE

Valve offsets should be the first performance menu function completed. The paver should be run until the hydraulic oil is at normal operating temperature before the value offset functions preformed. Once they are set, valve offsets should not need to be adjusted unless the Control Box has been moved to a new paver, or the hydraulic performance has changed. 1. Press the Auto button to select Valve Offset. This will automatically activate the value screen for Raise Offsets. The Raise Grade Correction Display Arrow will illuminate, and the Control Box will begin sending a raise correction signal to the valve.

3-9 Figure 3.04a System FiveTM Paver Operator's Manual

Chapter 3: Performance Menu

2. Turn the Grade Adjustment Knob counterclockwise, decreasing the Valve Offset value until the hydraulic cylinder is not moving. Then slowly rotate the Grade Adjustment Knob clockwise until the hydraulic cylinder just begins to move up.

Figure 3.04b

3. Press the Auto button to store the Raise Offset Value. Pressing the Auto button also switches the box to Lower Offset. The Lower Grade Correction Display Arrow will illuminate and the Control Box will begin sending a lower correction signal to the value.

3-10 Figure 3.04c

System FiveTM Paver Operator's Manual

Chapter 3: Performance Menu

4. Turn the Grade Adjustment Knob counterclockwise, decreasing the Valve Offset value until the hydraulic cylinder is not moving. Then slowly rotate the Grade Adjustment Knob clockwise until the hydraulic cylinder just begins to move down.

Figure 3.04d

5. Press the Auto button to store the Lower Offset Value. Pressing the Auto button will also return you to the Performance Menus. 6. Rotate the Grade Adjustment Knob to access another choice in the Performance Menu or press the Set/Menu button to exit.

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Chapter 3: Performance Menu

Averaging This setting changes the amount of dampening, or filtering, applied to sonic tracker and laser receiver measurements. It can be thought of as the time period over which a running average of the elevation measurement is calculated. A lower value will average fewer elevation measurements, allowing the system to react more quickly to smaller grade changes. This will make it more susceptible to fluctuations in temperature or small obstructions. A larger value will average more elevation measurements, preventing the system from reacting to undesirable items close to the reference. This will also make it less susceptible to fluctuations in temperature or small obstructions. • •

Averaging Value Range: 1-100 Factory Preset: 50 1. Press the Auto button to select Averaging.

Figure 3.05a

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Chapter 3: Performance Menu

2. Turn the Grade Adjustment Knob to select the desired value.

Figure 3.05b

3. Press the Auto button again to store the value. 4. Rotate the Grade Adjustment Knob to access another choice in the Performance Menu or press the Menu button to exit.

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Chapter 3: Performance Menu

Deadband Elevation Deadband is the area of the Working Window that is OnGrade. While the reference is within that area, the paver’s valves are idle (closed). Therefore the wider the Deadband (On-Grade area), the more a reference can move up or down without a correction being initiated. Once the signal from the reference is out of the deadband, System FiveTM will drive the hydraulics to place the reference back in the CENTER of the deadband. • •

Deadband Elevation Value Range : 1-30 mm Factory Preset : 3mm (.01', or 1/8") 1. Press Auto Button to select Elevation Deadband.

Figure 3.06a

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Chapter 3: Performance Menu

2. Turn the Grade Adjustment Knob to select the desired value - typically 3mm (0.01').

Figure 3.06b

3. Press the Auto button again to store the value. 4. Rotate the Grade Adjustment Knob to access another choice in the Performance Menu or press the Set/Menu button to exit. NOTICE The amount of Deadband should be carefully selected. Too small of a Deadband will cause the tow point cylinder to constantly hunt up and down while the sensor tries to find On-Grade. Too large of a deadband will not allow the sensor to send grade corrections to the valves, causing unwanted variations in the mat thickness.

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Chapter 3: Performance Menu

Deadband Slope Deadband is the area of the Working Window that is OnGrade. While the reference is within that area, the paver’s valves are idle (closed). Therefore the wider the Deadband (On-Grade area), the more a reference can move up or down without a correction being initiated. Once the signal from the reference is out of the deadband, System FiveTM will drive the hydraulics to place the reference back in the CENTER of the deadband. When the Deadband is changed it adds or takes away from the fine correction region (1% above or below On-Grade) of the slope sensor. It does not add this distance to the overall working range. • •

Deadband Slope Value Range : 025 - 750% Factory Preset : 075 1. Press the Auto button to select Slope Deadband.

Figure 3.07a

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2. Turn the Grade Adjustment Knob to select the desired value typically 075.

Figure 3.07b

3. Press the Auto button again to store the value. 4. Rotate the Grade Adjustment Knob to access another choice in the Performance Menu or press the Set/Menu button to exit. NOTICE The amount of Deadband should be carefully selected. Too small of a Deadband will cause the tow point cylinder to constantly hunt up and down while the sensor tries to find On-Grade. Too large of a deadband will not allow the sensor to send grade corrections to the values, causing unwanted variations in the mat thickness.

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Chapter 3: Performance Menu

Beeper Alarm When System FiveTM is in Automatic Mode and the Sonic Tracker gets a reference signal that is out of the Working Window (more than 2.0" from grade) a single audible beep will be heard. 1. Press the Auto button to select Beeper.

Figure 3.08a

2. Turn the Grade Adjustment Knob to turn the beeper ON or OFF.

Figure 3.08b

3. Press the Auto button again to store the choice. 3-18

4. Rotate the Grade Adjustment Knob to access another choice in the Performance Menu or press the Set/Menu button to exit. System FiveTM Paver Operator's Manual

Chapter 3: Performance Menu

Unit Set display to read in feet, inches, or centimeters. 1. Press Auto Button to select Units.

Figure 3.09a

2. Rotate the Grade Adjustment Knob to select a measuring unit (either feet, inches or centimeters).

Figure 3.09b

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Figure 3.09c

3. Press the Auto button again to store the value. 4. Rotate the Grade Adjustment Knob to access another choice in the Performance Menu or press the Set/Menu button to exit. NOTICE If the Unit is changed, the working window of the Sonic Tracker will have to be reset to grade.

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Test This tests the valves for shorts and disconnected valves. It test the Raise Valve first and then the Lower Valve. 1. Press the Auto button to select Test Mode.

Figure 3.10a

2. Display will read "Pass" if the raise valves test out OK. If there is a problem the display will read "Open" or "Short". 3. Press the Auto Button to test lower valves. The display will read "Pass" if the lower valves test out OK. If there is a problem the display will read "Open" or "Short". •

Good Valve

•

Valve NOT connected

•

Valve wires are electronically shorted Figure 3.10b

System FiveTM Paver Operator's Manual

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Chapter 3: Performance Menu

4. Press the Auto button once more to return to the Menu selections. 5. Rotate the Grade Adjustment knob to access another choice in the performance menu or press the Set/ Menu button to exit.

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System FiveTM Paver Operator's Manual

Chapter 4: Principles of Paving

Principles of Paving

Figure 4.0

Paver Components Modern pavers consist of two major units: The Tractor and the Screed. The primary function of the tractor is to propel the truck or paver feeding device, to convey and distribute the paving material and to tow the screed. The function of the screed is to strike off the material in preparation for further compaction. The screed is mounted to the tow arms at the screed pivot points and is attached to the paver at the tow points.

System FiveTM Paver Operator's Manual

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Chapter 4: Principles of Paving

How a Screed Works

Figure 4.01a

The screed on all modern pavers is of the "floating, self leveling" type. As the paver tows the screed unit forward, paving material flows under the screed. This causes the screed to float on the mat of material, thus establishing mat thickness. Since the screed is mounted to the paver only at the tow points, the screed is completely free to float up or down. The screed will always seek it's own "Planing Angle", or angle of attack, dependent on the combination of forces acting upon the screed.

4-2

Figure 4.01b

System FiveTM Paver Operator's Manual

Chapter 4: Principles of Paving

• •

If the screed angle of attack is increased the screed rises increasing the mat thickness. If the angle of attack is decreased, the screed will settle providing a thinner mat surface.

Figure 4.01c

Because the screed floats, it will not immediately react to a change in the tow point. It needs a certain amount of time or distance to make a correction in the mat thickness. If the tow point is changed by a unit of one, the paver must move one tow arm length before the screed will correct 63% of the elevation. After 2 tow arm lengths 83% of the correction is made and 3 tow arm lengths would account for 95%. It takes 6 tow arm lengths to achieve 100% of the elevation change. Considering that 95% of the change takes place after 3 tow arm lengths, this can be used in practical applications to qualify for full correction.

4-3 Figure 4.01d System FiveTM Paver Operator's Manual

Chapter 4: Principles of Paving

The same is true when making elevation changes with the manual thickness cranks.

Figure 4.01e

It is very important to check mat depth in several locations before making any elevation corrections. The surface being paved may have wheel ruts, dips and ridges that will give an untrue indication of overall mat depth. Check several spots to get an average. If an elevation change is made, wait 3 tow arm lengths for full correction. Too much cranking and stabbing will cause raise and lower changes that will produce an uneven mat surface.

4-4 Figure 4.01f System FiveTM Paver Operator's Manual

Chapter 4: Principles of Paving

There are four main forces acting on the screed at all times. These forces occur whether you are paving in manual or with automatics. A change in any one of the forces will cause the screed to rise or fall, changing the mat depth. The key to smoother paving is to keep these forces as constant as possible. Let's review each of the forces and what factors will have an effect.

Figure 4.01g

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System FiveTM Paver Operator's Manual

Chapter 4: Principles of Paving

Tow Point Force The tow point force (P) is the resistance to forward travel. The P force will remain constant if the paver is kept moving at a consistent speed at all times. If the paver is allowed to stop, the screed will settle in the fresh mat and leave a mark. The mark cannot be fully smoothed out by the roller and a bump will end up in the mat. This will show up in the profilograph readings and reduce your chance for any bonuses. Changing the speed of the paver will also cause the screed to rise and fall, affecting the mat thickness. The optimum paving speed is determined by the depth and width being paved and the rate at which material can be delivered to the job. Calculate the tons/ hour into feet per minute. Do not start and stop the paver.

Figure 4.02

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System FiveTM Paver Operator's Manual

Chapter 4: Principles of Paving

Truck Exchange is another tow point force. It is very important that truck exchanges be carried out as smoothly as possible to avoid disturbing the smooth, uninterrupted forward motion of the paver. The following lists some steps to take to avoid disturbance of the paving operation by trucks. 1. Stop the mix delivery truck close, but not too short of the paver. Always allow the paver to pickup trucks on the run. 2. Never allow the truck to bump the paver. Allowing trucks to bump the paver when backing up, can drive the screed into the mat and produces bumps and ridges which may not roll out. 3. Trucks applying and holding their brakes excessively while dumping their load may cause the paver to slow, which in turn will cause the screed to rise. The truck driver should apply only light pressure on the brakes, sufficient to maintain contact with the paver. 4. Dumping of material in front of the paver as the truck pulls away after emptying its load into the hopper, can cause the paver to ride over the pile of material with subsequent adverse effects on mat quality. Avoid trucks pulling away prior to completely dumping all material. Use a dump person to monitor and regulate truck movements in front of the paver.

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System FiveTM Paver Operator's Manual

Chapter 4: Principles of Paving

"M" Head of Material As described before, one of the primary functions of the paver tractor is to convey and distribute paving material onto the ground in front of the entire width of the screed. This material, once deposited in front of the screed is the head of material over which the screed will pass. One of the keys to smooth paving is to maintain this head of material as constant as is possible. The resistance to forward motion exerted by the head of material (M) is one of the major component of resistance to forward motion. Control of this force is a basic and necessary function of any paving operation. The volume and consistency of the head of material determines how much paving material flows under the screed and influences mat thickness and surface texture.

Figure 4.03a

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System FiveTM Paver Operator's Manual

Chapter 4: Principles of Paving

The most common factor affecting force "M", the head of material, is the following: Incorrectly Adjusted Automatic Feeder Controls: These systems, whether they are of the "hanging paddle" type or the sonic sensors should be adjusted to operate the auger/conveyor assemblies 95 to 100% of the time. On/off operation of the auger system will cause fluctuation in the head of material. The highest quality mat will generally result when a constant head of material is maintained across the entire width of the screed and the material almost covers the auger shaft. If the volume of paving material is too high, there is resistance to the travel of the screed. This causes the screed to rise and can result in ripples, auger shadows and long waves. It also results in increased auger wear.

4-9 Figure 4.03b System FiveTM Paver Operator's Manual

Chapter 4: Principles of Paving

"R" Reaction of Material Under Screed Ideally, every truck load of material delivered to the paver would be exactly like every other load with no variation. However, as a practical matter, changes in mix characteristics such as mix temperature, density, gradation, A.C. Content, segregation, etc., will affect the internal stresses developed within the mix, which in turn affects the resistance of the mix to flow under the screed. The key element to bear in mind is that the screed passing over the paving material will compact the material to a certain degree. Variable in the resistance of the material to compactive forces will cause changes in the screed's angle of attack, which in turn will affect mat thickness and therefore mat smoothness.

Figure 4.04

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Chapter 4: Principles of Paving

Mix Characteristics Gradation This aspect of the paving material will vary according to the intended use of the material as abase course, binder course or the final wearing surface. Normally, maximum aggregate size, ratio of aggregates, fines content and most importantly, asphaltic binder content, is specified by the contracting agency. Adherence to mix design specifications is usually the responsibility of the material supplier. Segregation is a material deficiency caused by a separation of the larger aggregate sizes from the bulk of the paving material. This condition is encountered especially in mixes with relatively large maximum size aggregate (example: 1" and larger, the so called "large-particle" mixes). When paving material is deposited in piles, as in an asphalt plant silo, a haul truck, a paver hopper, on the ground in front of the paver in a windrow, or on the ground in the auger chamber, segregation can and does frequently occur. NOTICE The areas listed above where segregation can occur are all areas that the material may encounter before being laid down as a mat. Therefore, these areas of segregation must be addressed prior to any paving. The screed cannot rectify segregation during the paving process.

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System FiveTM Paver Operator's Manual

Chapter 4: Principles of Paving

Segregation can also be the result of improper hopper dumping: Duration normal operation, the vibration of the pavers hopper will cause segregation. Therefore, dumping the hopper after each truck should be avoided because material that has rolled to the outside of the hopper (the large aggregate) will fill the conveyors and auger chamber and result in a segregated area behind the paver with a noticeable difference in surface texture. If It Doesn't Look Right, It Isn't Right: Surface and texture irregularities indicate that the homogeneous characteristics of the material in the mat have been interrupted, which usually results in bumpiness and premature failure of the pavement in those areas. Segregation can also be the result of excessively worn augers: "Center Streak" segregation can be caused by worn "Kicker Paddles" at the center chain cause or near the outside auger bearings. In fact center streak segregation is frequently caused by incorrect arrangement of the auger segments adjacent to the auger chain case. (Consult the Manufacturers Manual). "Center Streak" segregation is also caused by feeder gates being set to tow. Adjust as necessary to provide sufficient uniform material at the center of the paver. NOTICE "Center Streak" segregation can be limited and even eliminated by slowing paving speed. 4-12

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Chapter 4: Principles of Paving

Mix Temperature A common paving problem is inconsistent temperatures in the asphalt mix. As the material cools it loses its viscosity making it more difficult to compact. If the resistance to compaction increases, the screed will naturally increase its angle of attack and begin to float up. This will change the mat depth, resulting in bumps in the surface. If the mix and or screed temperature are too low, the screed may no longer slide smoothly over the material and a tearing of the mat will occur. Some simple steps to take to control temperature variations: A. Ensure that haul trucks take the shortest, most practical route to the paver. Make certain that all trucks take the same route to the paver. B. Make sure that the trucks arrive at the same order in which they were loaded at the asphalt plant. C. Ensure that no bunching of trucks occurs at the paver, with several trucks waiting to dump their loads. D. Match lay-down rate to material delivery rate. NOTICE Temperature problems may occur will before the time the material is loaded into the trucks, or during the trip to the paver. They can be the result of temperature variations at the plant. If this is not addressed prior to delivery of material to the paver, waviness in the he mat will be the result. 4-13

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Chapter 4: Principles of Paving

"W" Weight of Screed For weight of screed force "W" to remain constant, the weight of the screed or the downward pressure exerted by the screed on the paving material should not change. The weight of the screed is measured in pounds per square inch.

Figure 4.05a

Members of the paving crew climbing on and off the screed will have some affect on the weight of screed force. The primary factor affecting this force is changing the width of the screed. Extendible screeds weigh the same whether they are fully retracted or fully extended. The difference is the wider the extension of the screed the greater the surface area of paving material to support. An extended screed has fewer psi, which means less compaction, causing the screed to raise.

4-14 Figure 4.05b System FiveTM Paver Operator's Manual

Chapter 4: Principles of Paving

Quality of Base Being Paved There are factors other than the four main forces that can have an effect on the quality of the mat. An important one is the quality of the base to be paved. It makes more sense to build smoothness from the base up, than to try to smooth a road in the last lift of paving. However, on overlay paving jobs we have to work with what we have. Remember that a mat which appears smooth immediately behind the paver, may actually contain areas of considerably varying thickness of material as a result of undulations in the base being paved. Due to the principle of "Differential Compaction" high spots will not compact as much as the low, therefore allowing some of the irregularities to be rolled back onto the mat. To minimize this problem, lay a leveling course in the low spots or pave multiple lifts to average out the irregularities.

Figure 4.06

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Chapter 4: Principles of Paving

Rolling Techniques A well laid mat can end up with a poor ride quality if proper rolling methods are not followed. Consult your compaction equipment manufacture's manuals and handbooks on compaction techniques.

Controlling Mat Quality The primary purpose of the asphalt paver is to place a smooth mat of material. The primary function of System Five is to control the vertical position of the screed in relation to the surface being paved. Automatic grade and slope control systems can help tremendously in controlling mat smoothness but mat quality is also dependent on the following factors: A. B. C. D. E.

Non-Stop, Continuous Operation of Paver Constant Speed of Paver Truck Exchange Head of Material Mix Characteristics 1. Gradation 2. Segregation 3. Mix Temperature F. Screed Compaction G. Quality of Base Being Paved H. Rolling Techniques NOTICE

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Changes in any of these factors will cause a change in mat thickness, density, surface appearance and mat quality. If changes must be made, make them as gradually as possible. Abrupt changes in any of the above factors will produce rapid changes in mat thickness, adversely affecting mat quality.

System FiveTM Paver Operator's Manual

Chapter 5 : Getting Ready to Pave

Getting Ready to Pave

Figure 5.0

This chapter is designed to get the paving crew started using System FiveTM. The job application and the desired results will determine what type of non-contacting controls should be used; i.e. sonic, slope, laser and SAS. The components should be mounted on the paver and then the paver itself must be properly set up. 5-1

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Chapter 5: Getting Ready to Pave

Connect the cables into the Control Box:

Figure 5.01

NOTICE Due to different types of machine configuration, your cable connections may vary.

Machine Setup To start paving with System FiveTM, set up the paver just as you would under manual control. Place the screed on blocks or lath set for the desired paving thickness. Make sure you account for material compaction. 5-2

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Chapter 5 : Getting Ready to Pave

Figure 5.02a

Center the tow point cylinders to maximize travel in raise or lower directions. You can use the jog switch on the System FiveTM Box (Power must be on) or the switch provided with the paver.

5-3 Figure 5.02b

System FiveTM Paver Operator's Manual

Chapter 5: Getting Ready to Pave

Using the manual thickness adjustment cranks or hand cranks on the paver, null the screed and set the proper angle of attack. Next, turn on the auger feeder controls to place the asphalt in front of the screed.

Figure 5.02c

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System FiveTM Paver Operator's Manual

Chapter 5 : Getting Ready to Pave

Sonic Tracker Setup When installing and positioning the Sonic Tracker IITM, first connect the coil cord to the Tracker. Then bolt the Tracker to the bracket, and visually check to get the Sonic Tracker plumb. Make one wrap of the coil cord around the "L"-Bar. This will act as a strain relief for the connector on the Tracker. Be sure the coil cord snap hook is in place and secure.

Figure 5.03

System FiveTM Paver Operator's Manual

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Chapter 5: Getting Ready to Pave

Control Box Setup - Elevation Once the Sonic Tracker has been positioned over the reference, the Control Box can now set the Tracker On-Grade. Flip the power switch to the on position press and hold the survey button for 1 second until the box beeps and the green OnGrade Bar is displayed.

Figure 5.04a

Next, make the display read the same number as depth of mat to be laid. Press and hold the "Set" button with one hand. With your other hand, turn the grade adjustment knob to change the display to the height of the blocks under the screed. Release the "Set" Button and the value will be saved.

5-6 Figure 5.04b System FiveTM Paver Operator's Manual

Chapter 5 : Getting Ready to Pave

Using Set will not change the existing mat thickness, it only changes the reference number viewed on the display.

Figure 5.04c

Press the Red Button and the Red LED will light up. You are now in automatic mode and can begin paving.

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Chapter 5: Getting Ready to Pave

After you begin paving it is important to check the mat depth to insure the desired thickness is being laid. The blocks initally placed under the screed may cause the mat to be too thick or thin. Check the mat several times to get an average before making any corrections.

Figure 5.04d

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Chapter 5 : Getting Ready to Pave

If a 2.50 inch mat is required, but a 3.0 inch mat is being laid, then an adjustment is necessary. You must first get the box to display the same number as the mat depth. Press and hold the "Set" button with one hand. With other hand turn grade adjustment knob to read 3.0 inches. Press the red auto button to put the system back in automatic control.

Figure 5.04e

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System FiveTM Paver Operator's Manual

Chapter 5: Getting Ready to Pave

With the paver moving and in auto, slowly dial the display from 3 inches down to 2.5 inches. How fast you turn the knob depends on how smooth you want the transition to take place. Highways require gradual changes, parking lot require quick changes. The display should now read the depth of the mat being laid.

Figure 5.04f

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Chapter 5 : Getting Ready to Pave

Control Box Setup - Cross Slope The slope sensor should already be mounted on the transverse beam of the paver. The sensor can talk to both control boxes, but only one at a time. The sensor communicates to the Control Box through the cable.

Figure 5.05a

To pave using cross slope you must first calibrate the slope sensor, to the screed. Find a smooth area where the screed can rest evenly across its entire surface. Using a laser, a Smart Level, or a slope board, that itself has been calibrated, check the cross slope and direction of fall of the ground.

5-11 Figure 5.05b System FiveTM Paver Operator's Manual

Chapter 5: Getting Ready to Pave

Now place the screed on the ground and null it out. Flip the power switch to the On position and push the Slope Mode Button. The yellow LED next to the cross slope symbol will illuminate.

Figure 5.05c

To find out the slope and direction of fall the slope sensor thinks the screed is resting on, push the survey button for 1 second to lock sensor On-Grade. If the box is displaying and On-Grade bar and a slope value that is identical to the laser or Smart Level then you can begin paving. Make sure to push the Auto Button.

5-12

Figure 5.05d

System FiveTM Paver Operator's Manual

Chapter 5 : Getting Ready to Pave

If the slope displayed in the box does not match the surface, then the sensor must be calibrated. Press and hold the "Set" button with one hand. With your other hand, turn the grade adjustment knob to change the display to match the slope of surface. Release the "Set" button and the value will be saved.

Figure 5.05e

NOTICE Using Set will not change the slope, it only changes the slope value viewed on the display. Press the Red Button and the Red LED will light up. You are now in Automatic Mode and can begin paving.

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Chapter 5: Getting Ready to Pave

Once the slope sensor is calibrated and you are ready to begin paving, you may find the existing surface does not have the same slope as the finish design. In order to produce a smooth transition, begin paving at the existing slope and slowly turn the grade adjustment knob to change the cross slope to the correct percentage.

Figure 5.05f

If a smooth transition is not required, then dial in the desired slope and begin paving.

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System FiveTM Paver Operator's Manual

Chapter 6: Tracker Placement

Tracker Placement Raise or lower the tracker bracket to position the tracker at the proper height above the grade reference. The tracker has a total working range of 14 to 55 inches. For paving applications the recommended working height would be from 14 to 24 inches. At 55 inches the sonic footprint would be very large and the tracker may pick up an undesired reference. The tracker also compensates for temperature changes only within the bail range. Placing the tracker too far from the reference may not allow for accurate temperature compensation.

6-1 Figure 6.0

System FiveTM Paver Operator's Manual

Chapter 6: Tracker Placement

Position the "L"-Bar horizontally so the tracker will be over the reference. For example, when tracking a curb and gutter, place the screed or extension flush with the edge of gutter and slide the "L"-Bar so the Tracker is over the lip of the gutter.

6-2 Figure 6.01a System FiveTM Paver Operator's Manual

Chapter 6: Tracker Placement

The "L"-Bar can also be mounted to a bracket on the screed extension. This would work well in applications where the reference will not be a constant width and requires the extension to be moved in and out. Mounting to the extension will make it easier to keep the tracker over the reference.

6-3 Figure 6.01b System FiveTM Paver Operator's Manual

Chapter 6: Tracker Placement

When tracking a curb and gutter, keep the tracker 14 to 24 inches above the lip of gutter. If the tracker is placed too high, the sonic cone may pick up an unwanted surface, such as the face of the curb.

Figure 6.01c

For joint matching and tracking sub-grade or most surfaces keep the tracker between 14 to 24 inches. A good rule of thumb is to set the tracker about 18 inches from the reference.

6-4 Figure 6.01d System FiveTM Paver Operator's Manual

Chapter 6: Tracker Placement

Temperature and atmospheric conditions will have an effect on the speed of sound. In paving applications you can get a dramatic and rapid change in air temperature. A temperature bail is attached to the tracker to compensate for these variations. If you are on a job where there are high winds and/or large temperature fluctuations, lower the tracker closer to the reference.

Figure 6.01e

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System FiveTM Paver Operator's Manual

Chapter 6: Tracker Placement

If a mechanical ski with an elevated string or wire is being used, make sure the string/wire reference is a minimum of 4 inches above the ski. When paving with a mechanical ski through super elevations the ski will tend to pull away from the paver and may even tip to one side. Elevating the string at least 4" will insure the ski stays out of the working window. It is also important to place the tracker in the center of the ski to maximize the averaging length. If you are using a 30' ski, then the sensor should be placed 15' from the end of the ski. For every 1' positioning error from the center of the ski, you lose 2' effectivity of the ski. An example of this would be if the sensor is moved foreword or backward 2 1/2 ' (12 1/2' from the end) you are using a 25' ski.

Figure 6.01f

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System FiveTM Paver Operator's Manual

Chapter 6: Tracker Placement

Some jobs may require the mat be laid to a specified elevation. In an application like this an elevated stringline or wire may be set up. As was mentioned in the operation section, the sonic tracker has a built in working window that will prevent the screed from diving if the tracker loses the stringline reference. Position the tracker over the stringline and set the distance between 18 and 24 inches.

Figure 6.01g

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System FiveTM Paver Operator's Manual

Chapter 6: Tracker Placement

Sometimes the surface to be paved contains pot holes or the surface is too broken up to use as a joint match reference. Setting an elevated stringline is too time consuming especially for small, divided up projects. In these applications, surface stringline would be a good alternative. (See section on Setting Surface Stringline).

Figure 6.01h

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System FiveTM Paver Operator's Manual

Chapter 6: Tracker Placement

We've discussed how far a tracker should be positioned from the reference, now we need to look at where the tracker should be placed in relation to the screed. As a tracker is moved closer to or further away from the screed, the response of the screed to an elevation correction changes. A rule of thumb is to place the tracker about 1/3 to 2/3 the length of the tow arm forward of the screed pivot point.

Figure 6.01i

If the tracker is not placed between these points then incorrect screed responses could result. Let's look at a couple of examples. If the tracker is placed directly at the screed pivot point, you can see exactly where the screed is relative to the grade reference. This is good, but the problem is we have no feedback from the tow point cylinder, which is what we are using to make the grade control changes.

6-9 Figure 6.01j System FiveTM Paver Operator's Manual

Chapter 6: Tracker Placement

If the tracker gets closer to the reference, it sends a raise correction signal to the valve and the tow point cylinder begins to move up. Because the screed floats it does not react immediately to the tow point movement so the tracker continues to send raise correct signals to the valve. By the time the screed gets to grade, (approximately 3 tow arm lengths) the tow point cylinder has moved too far causing the screed to continue raising. The tracker senses this over correction and sends a lower signal to the tow point cylinder, repeating the whole process in the other direction. Therefore, with the tracker mounted at the screed pivot point, long waves in the mat will be produced because there is no feedback from the tow point cylinder to the screed.

Figure 6.01k

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Chapter 6: Tracker Placement

To compensate for no tow point feedback let's place the tracker directly at the tow point where we are making the grade corrections. At this point we can keep the sonic tracker an exact distance from the grade reference. Any tracker elevation changes will cause the tow point cylinder to move right away. The problem with the tracker placed here is we have no feedback from the screed.

Figure 6.01l

If any of the forces acting on the screed change then the screed will rise or fall without the tracker sensing the movement. For example if the amount of material in front of the screed was decreased, the head of material force "M" also decreases and the screed would begin to fall. The sonic tracker would keep the tow point cylinder on grade, but not the screed since there is no feedback.

6-11 Figure 6.01m System FiveTM Paver Operator's Manual

Chapter 6: Tracker Placement

The best place for the tracker is in the 1/3 to 2/3 zone, but where do we position the tracker within that area? That depends on what end result of paving you are trying to achieve. As the tracker is moved further back towards the screed it becomes more reactive. At the 1/3 point a 1/4 inch correction at the tracker will cause a 3/4 inch correction at the tow point. Another way to look at it is the "Net Tow Arm Length". A paver with a 9 foot tow arm and no sonic tracker will take 27 feet (9 feet x 3 tow arm lengths) to see 96% of the elevation change. If a tracker is placed at the 1/3 point or 3 feet in front of the screed pivot point then the paver must only move 9 feet (3 feet x 3 tow arm lengths) for 96% of the elevation change. The tracker is measuring the distance to the reference so its position along the tow arm becomes the net tow arm length. A more reactive screed would be beneficial for applications where it is important to match the reference such as tracking a curb and gutter or matching a joint.

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Figure 6.01n

System FiveTM Paver Operator's Manual

Chapter 6: Tracker Placement

As the tracker is moved further forward the screed becomes less reactive. A tracker placed at the 2/3 point and looking for a 1/4 inch correction will only cause the tow point to move 3/8 inch. The net tow arm length is now 18 feet (6 feet x 3 tow arm lengths). This would be a better tracker position for applications where smoothness is desired such as mainline paving or when using a mechanical or noncontacting (SAS) ski.

Figure 6.01o

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Chapter 6: Tracker Placement

Notes

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Chapter 7: Stringline

Stringline Setting Surface Stringline Surface Stringline is a great replacement for a contacting averaging ski, or where no reference is available or practical. The purpose of a ski is to average out the irregularities of the surface being paved. Although a good idea in principle, averaging skis seldom work well in practice. They are bulky, complex, cumbersome and get broken easily. When they are working they still only average over their length. Surface Stringline is better. As a Surface Stringline is stretched over the ground it levels out the high places and bridges the low, creating a very natural average over a distance as long as 500 feet. Since the Sonic Tracker IITM is non-contacting, it can track Surface Stringline without deflecting it, producing an extremely smooth surface. Additionally, the smoothness of the surface you will get from Surface Stringline is verifiable before you begin paving. Just sight down the string and you can see how good the job will be. If there will be problem areas, mark the spots and either fix them ahead of time or use the marks as a "I told you so" for future reference. You can also use the same Sonic Stringline as a steering guide.

7-1 Figure 7.0 System FiveTM Paver Operator's Manual

Chapter 7: Stringline

Position the tracker 14 to 18 inches above the stringline.

Figure 7.01a

NOTICE It is important to use a stringline with a diameter at least 1/8" thick. The sonic tracker can detect a smaller diameter stringline, but when stretched on the surface to be paved the surface below the stringline will be within the working window so you want to make sure you have a strong return signal.

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Chapter 7: Stringline

To setup surface string, simply drive a concrete nail into the existing surface to be overlaid and tie the stringline to the concrete nail.

Figure 7.01b

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Chapter 7: Stringline

Roll out the stringline to the desired length. Pull tight and secure to another nail at the opposite end. The tightened stringline will rest right on top of the existing surface. When the sonic tracker sends out a sound wave, the first thing the tracker sees will be the reference stringline.

Figure 7.01c

Since the stringline has been pulled tight, any small variables in the existing surface will be bridged. You now have 500 ft. ski.

Figure 7.01d

The operator may use the surface stringline for steering and grade control. Trucks and other traffic can drive right over the top of the surface string with out causing any grade control problems or damage to the reference 7-4

The surface stringline is a verifiable grade reference, what you see is what you get. Any potential problems can be pointed out to the inspector before you pave. Try it, it really works! System FiveTM Paver Operator's Manual

Chapter 7: Stringline

Setting Elevated Stringline On some projects the asphalt must be laid to a specified elevation. For this application an elevated stringline must be set. The stringline will usually be set up at a 1' or 2' "hike up" from finished grade. The stringline is set referencing hubs or lath placed by the surveyor.

Figure 7.02a

Sonic Stringline provides an inexpensive, easy to set up, continuous reference that takes the best advantage of the non-contacting feature of the Sonic Tracker IITM. By taking a few minutes to set up a stringline the Tracker can transfer grade to the paver 39 times per second! The stringline also becomes a great visual reference for the job. Any mistakes in a hub elevation can be quickly spotted by just sighting down the string.

7-5 Figure 7.02b System FiveTM Paver Operator's Manual

Chapter 7: Stringline

NOTICE Although Topcon’s Sonic Tracker will work with many sizes and types of stringline, for best results werecommend an 1/8 inch diameter nylon stringline. Using steel wire or a plastic coated stringline with a smooth surface is not recommended. If the Tracker will track the ground, but will not track a 1/8 inch diameter stringline, clean or replace the transducer.

1. Place the Sonic Grade Clips on stakes and drive the stakes approximately 6 to 8 inches away from, but in line with, the hubs (Do Not disturb the hubs).

7-6 Figure 7.02c System FiveTM Paver Operator's Manual

Chapter 7: Stringline

2. Using an anchor pin at each end, roll out the Sonic Stringline the length of the working area and pull the stringline tight. 3. After the stringline has been pulled tight, place it into the ‘fingers” of each Sonic Grade Clip.

Figure 7.02d

4. Decide what the Sonic Stringline hike-up (the distance from Finished Grade to the Sonic Stringline) should be: in this case, 2 feet. Make a cut/fill lath using a lath and a Topcon Cut/Fill Decal. 7-7

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Chapter 7: Stringline

Measure, from the bottom of the lath, the desired hike-up and make a mark at that point. Place the Cut/Fill Decal on the lath with “0” on the point you marked.

Figure 7.02e

5. Next, set the cut/fill lath on the hub and read the cut or fill from the grade stake next to the hub. Adjust the clip up or down until the stringline crosses the cut/fill lath at that point. A cut of .25 feet

7-8 Figure 7.02f System FiveTM Paver Operator's Manual

Chapter 7: Stringline

• The stringline is now set to 2 feet above finished grade.

Figure 7.02g

• Repeat this process at each station before starting to pave.

Figure 7.02h

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Chapter 7: Stringline

•

Setting Stringline to Projected Slope Jobs with slope transitions or super-elevations must have the stringline set to the “projected slope”. Failure to do this will produce an elevation error at the edge of the road as the slope is changed. To set the stringline to the projected slope, first set up the string at the desired hike up as shown in the previous pages. Next, raise or lower the stringline to compensate for the % slope and the distance from edge of the road to the stringline. [RISE = (RUN)(%)]. If the road is rising away from the stringline, the stringline will need to be lowered. If the road is sloping down from the stringline, the stringline will need to be raised. This adjustment is needed at each station. • Example: 2.0% Cross Slope with 2 feet offset.

Figure 7.02i

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Chapter 7: Stringline

• Example: 3.0% Cross Slope with 2 feet offset.

Figure 7.02j

On some jobs, it may be more practical to secure the stringline directly to the grade stake next to the hub. First, mark the lath with a 2 or 3 feet “hike up” or boot” above grade, just as you would to check grade with an eye level or pulling a string across the street.

7-11 Figure 7.02k System FiveTM Paver Operator's Manual

Chapter 7: Stringline

Secure an anchor pin at each end of the stringline and pull the stringline tight. At each station, staple or ty-rap the stringline directly to the witness lath so the stringline is at the desired hike-up.

Figure 7.02l

Due to the height of some stakes the Tracker may need to be raised or the tops of those stakes may need to be cut off.

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Chapter 7: Stringline

• Making a Grade Verification Lath Verifying grade requires measuring the distance from the asphalt to the Sonic Stringline. Because the hubs are offset from the edge of road and the Sonic Stringline is a predetermined “hike-up” above Finished Grade, a simple tool called a “Grade Checking Lath” can be constructed. This can be easily done using lath, a level bubble and simple hand tools. In this example assume that the hub offset from the edge of road is 1.5 feet and that the “hike-up” is 2.0 feet. Construct a Grade Checking Lath as shown below.

7-13 Figure 7.02m System FiveTM Paver Operator's Manual

Chapter 7: Stringline

• Verifying Grade To verify grade, set the Grade Checking Lath on the newly laid mat edge so that the level bubble extends over the Sonic Stringline shown below.

Figure 7.02n

7-14

Tilt the Grade Checking Lath until the level bubble is centered. Finished Grade is correct when the level just touches the Sonic Stringline. System FiveTM Paver Operator's Manual

Chapter 8: Smoothtrac® (SAS) Set Up

Smoothtrac® (SAS) Set Up Topcon's Smoothtrac® is a non-contacting averaging system that uses multiple sonic trackers to smooth out the bumps and dips in a mat surface. The non-contacting design allows full maneuverability of the paver when turning around, backing up or passing over obstacles without lifting or removing the beam. The screed man can adjust mat thickness on the control box while standing on the screed. The Smoothtrac® is mounted to the tow arm of the paver, and connects to System FiveTM with the same coil cord used for the Sonic Tracker.

Figure 8.0

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System FiveTM Paver Operator's Manual

Chapter 8: Smoothtrac® (SAS) Set Up

When mounting the SAS to the paver there are a few simple steps to follow First, if the ski is not in one piece, connect both halves together.

Figure 8.01a

Next, mount the "L" bars to the brackets on the tow arm. The outside "L" bar can be attached so it points up or down. The position will depend on how tall the tow arm is off the ground. For pavers with a tall tow arm, mount the "L" bar in the downward position. For shorter tow arms, mount in the upward position. Place locking collars on bars and adjust so they are parallel with one another before tightening with an Allen wrench. This will allow the ski to move freely when adjustments need to be made without falling off.

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Chapter 8: Smoothtrac® (SAS) Set Up

Bend "L" bars so they are aligned in the same position and fold inwards so they are close to the paver. Make sure clamp handles are loose so bars can move.

Figure 8.01b

Lift ski and slide over "L" bars. Adjust the ski so it is approximately 2 1/2 feet off the ground. Slide the locking collar up to the ski and lock in place. Helpful hint, the ski will be easier to mount if the end beams are folded in. Bend "L" bars so they are aligned in the same position and fold inwards so they are close to the paver. Make sure clamp handles are loose enough so bars can move.

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Chapter 8: Smoothtrac® (SAS) Set Up

Lower each of the Tracker hangers on the SAS and mount a Sonic Tracker using the "L" handle bolt. An extra washer may need to be added so the "L" handle does not block the cable connection.

Figure 8.01c

Connect the SAS coil cable to each tracker to the Sonic Tracker coil cord. Make sure to loop the coil cable through the "U" hangers to keep it from getting damaged. Don't forget to install temp bails before paving!

8-4 Figure 8.01d

System FiveTM Paver Operator's Manual

Chapter 8: Smoothtrac® (SAS) Set Up

Positioning the SAS The SAS should be positioned so the Sonic Trackers are 14 to 24 inches from the grade reference. As with single tracker operation, the "lower the better" is a good rule of thumb for paving applications. This will help minimize the variable temperature conditions that can cause erratic signals. The beam does not have to be perfectly level because each tracker averages the distance to the reference individually.

Figure 8.02a

With SAS be careful when the screed is raised, that the front tracker does not hit the ground. If needed the tracker bracket can be folded back when raising the screed to keep the tracker from hitting obstructions.

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Chapter 8: Smoothtrac® (SAS) Set Up

The trackers can be placed so all four are over the reference, or the back tracker can be set over the freshly laid mat. The best method is the one you are presently using or the one in which you are most comfortable.

8-6 Figure 8.02b System FiveTM Paver Operator's Manual

Chapter 8: Smoothtrac® (SAS) Set Up

In some applications the grade reference outside the screed extension may not be in satisfactory condition, such as the shoulder of a road or the broken and warped edge of pavement. Traditionally the screedman would manually adjust mat thickness on that side of the paver. The non-contacting SAS can be set up over the screed so full automation can be used. The first three trackers will reference the existing grade and the back tracker will reference the mat just laid.

Figure 8.02c

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System FiveTM Paver Operator's Manual

Chapter 8: Smoothtrac® (SAS) Set Up

When paving with the screed extensions out, there may be a large "head of material: which could be picked up by the Sonic Tracker. If this happens determine how far forward the tracker must be placed on the beam to not pickup the mix and drill a new mounting hold for the tracker hanger. The SAS coil cable will easily reach the tracker.

Figure 8.02d

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System FiveTM Paver Operator's Manual

Chapter 8: Smoothtrac® (SAS) Set Up

Placement of Sonic Averaging System The center connection point of the SAS is the balance point. The position of the balance point to the tow arm is very critical. By moving the balance point, the performance of the system is greatly affected. The balance point of the beam should be located 1/3 to 2/3 the distance from the pivot point of the screed to the tow point cylinder. Placing the balance point closer to the 2/3 point (near the tow point cylinder), will cause the system to have a slower reaction time. This would be good for smoothness or for mainline paving. Placing the balance point near the back 1/3 (closer to screed) will cause the system to have a faster reaction time. This would be good for a combination of smoothness and joint matching. To determine where to position the SAS on the paver, start by measuring the length of the tow arm. Divide the total length by three. This will give you the placement of the balance point of the SAS on your machine.

8-9 Figure 8.03a System FiveTM Paver Operator's Manual

Chapter 8: Smoothtrac® (SAS) Set Up

Once the SAS has been installed, the System Five control box will automatically configure for SAS when powered on. The box will check to see how many trackers are connected and average over that amount. Getting the System Five Box ready to pave is the same as with one tracker. 1. Block screed for required mat thickness 2. Center hydraulic rams 3. Null screed and turn on augers to place material in front of the screed 4. Place trackers over reference 5. Push survey button on Box to lock trackers On-Grade. 6. Push and hold set button while dialing in mat depth. 7. Put Control Box in Auto and begin paving.

Figure 8.03b

NOTICE

8-10

It is not necessary to start paving in manual as is traditionally done when using a mechanical ski. If the setup procedures are followed correctly, paving with the SAS can and should start in automatic. System FiveTM Paver Operator's Manual

Chapter 8: Smoothtrac® (SAS) Set Up

The SAS system has been designed to discontinue operating when one of the Trackers fails. When a failure occurs, the control box will flash "ERR" followed by a number from 1 to 4. The number represents the Tracker which failed, making troubleshooting easy and fast. To reset the control box once a new tracker has been installed, or if the tracker has been removed and only three trackers will be used, turn the power off then on. The control box will reconfigure to the number of trackers. Changing the number of trackers may change the average distance. Resurvey the Control Box to lock SAS On-Grade. Once one of the Trackers has been eliminated from the averaging, the balance point of the beam will have changed. If the faulty Tracker is not replaced the beam will need to be repositioned to adjust for the new balance point. It is strongly recommended, if the first or last Tracker fails, to replace it with one of the Trackers from the middle of the beam. This will insure that the balance point is not outside of the 1/3 to 2/3 rule. NOTICE A number reading of "1" could mean the first or last Tracker has failed depending on which side of the paver the beam has been mounted. The SAS cable is labeled with numbers at each connector for easy identification.

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Chapter 8: Smoothtrac® (SAS) Set Up

Figure 8.03c

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System FiveTM Paver Operator's Manual

Chapter 9: Applications

Applications What type of controls you should use for paving depends on what result is required for the finish product. Some projects are looking for smoothness and improved rideability. Others are concerned with mat thickness and some require the new asphalt to match curb and gutter or existing grades. Topcon's System Five is very versatile and can be used in all these applications. The following are a few examples of what controls might be used and how to set them up.

Paving City Streets with Sonics When paving city streets the general requirement is to lay a mat that is so many inches above the base at the centerline and to match curb and gutter. For this application sonic control will be used on both sides.

Figure 9.01a

NOTICE Before paving make sure the machine is properly setup, cross slope is calibrated and trackers are set in the correct position. (See Chapters - Getting Ready to Pave & Tracker Placement.) System FiveTM Paver Operator's Manual

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Chapter 9: Applications

Position right Tracker over lip of gutter and left Tracker past the centerline on the base material.

Figure 9.01b

Turn Boxes on, then "Survey" and "Set" the displays to read the depth of asphalt to be laid.

Figure 9.01c

Put boxes in Automatic and begin paving. Check depth of mat at centerline and verify joint is matching at lip of gutter. After compaction make necessary adjustments on the Control Box. NOTICE If the road width varies, it will be easier to keep the Tracker over the gutter if the Tracker is mounted to the extension on the paver. 9-2

System FiveTM Paver Operator's Manual

Chapter 9: Applications

To pave the other side of the road, position the left Tracker over the lip of the gutter and place the right Tracker over the new mat.

Figure 9.01d

"Survey" boxes On-Grade and "Set" the displays to read the depth of asphalt to be laid. Put boxes in Automatic and begin paving. Check to make sure joints are matching after compaction.

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Chapter 9: Applications

Paving City Streets with Cross Slope Another option is to pave the street using cross slope and sonic control. The Tracker is positioned over the lip of gutter on one side and cross slope is dialed in for the crown on the other. This method may have to be modified due to the fact that in many cases the curbs may be poured at different elevations across the street. Even though the curb was poured out of tolerance, it may have passed inspection and the asphalt needs to match the curb and gutter. If the curbs are at different elevations, it is impossible to pave a typical design slope on both sides of the street. A cross section design of a 36 feet wide street with a 2.0% slope will produce a .36 feet rise at centerline.

Figure 9.02a

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System FiveTM Paver Operator's Manual

Chapter 9: Applications

If the curbs are at different elevations, a .36 feet rise at centerline will produce incorrect slopes.

Figure 9.02b

When System FiveTM is used to pave a true 2.0% slope, the crown of the street will not be at the centerline.

Figure 9.02c

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System FiveTM Paver Operator's Manual

Chapter 9: Applications

To pave from uneven curbs using slope control choose the side of the road with the highest curb and position the tracker over the curb. Set the other side for the desired cross slope and begin paving.

Figure 9.02d

To keep the centerline in the middle of the road, the second pass will have to be set up with Sonic Control on each side of the paver. The left Tracker will match the lip of the curb and the right side Tracker will follow the new mat. The cross will not be consistent on this side of the roadway, but the joints will match.

9-6 Figure 9.02e System FiveTM Paver Operator's Manual

Chapter 9: Applications

The curb elevations can be easily spot checked using a fast leveling RL-HB rotating laser. Set the laser at the lip of one curb, then use the detector and a folding rule to take a reading on the other curb. Spot check every 25-50 feet by just moving the laser.

Figure 9.02f

Paving Streets Through Intersections As you pave city streets you will come upon an intersection where the curb will not continue. There are a couple of methods for controlling grade through the intersection. Method 1 For this method the base of intersecting road will be used as the reference. With both sides in Elevation Control, pave to the intersection.

9-7 Figure 9.03a System FiveTM Paver Operator's Manual

Chapter 9: Applications

Just before the right Tracker reaches the end of the curb, put the Control Box in Manual Mode by pushing the Red Auto Button.

Figure 9.03b

Without stopping, continue paving until the Tracker is on the base material of the intersecting road. "Survey" the Tracker On-Grade on the new reference and put back into Automatic Control.

Figure 9.03c

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System FiveTM Paver Operator's Manual

Chapter 9: Applications

Pave through the intersection and just before the Tracker reaches the curb on the other side, put the Control Box in Manual mode.

Figure 9.03d

Without stopping, continue paving until the Tracker is back on the lip of the curb. "Survey" the Tracker OnGrade and put back into Automatic Control.

Figure 9.03e

System FiveTM Paver Operator's Manual

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Chapter 9: Applications

NOTICE You may find after surveying the Tracker on the curb that the number has changed slightly from the curb on the other side of the intersection. This is due to the different depth of the base below lip of curbs. While paving, slowly dial the display back to the previous number. Method 2 Sometimes the base of the intersecting road is too rough to use as a reference. A great alternative is to use a simple piece of stringline. Take a section of 1/8" diameter string and nail or secure it to the curb. Pull the string tight through the intersection and nail or secure it to the other curb. If the intersecting road has a crown, hike the stringline up in the middle of the road to place the string at the proper height. A hub or a stake with a piece of wire to hold the stringline works fine.

9-10

Figure 9.03f

System FiveTM Paver Operator's Manual

Chapter 9: Applications

This constant reference will give you complete control through the intersection and will also insure that you tie in perfectly to both curbs.

Paving Intersections with Cross Slope When paving with slope, intersections do not require any adjustments if the "mainline" cross slope does not change. If the slope does change, then a combination of slope and Tracker should be used.

Figure 9.04a

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System FiveTM Paver Operator's Manual

Chapter 9: Applications

Put the slope side of System Five Box in Manual just before the slope of the intersection begins to change. Switch from slope to elevation control on the box and "survey" the Tracker On-Grade.

Figure 9.04b

Figure 9.04c

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Chapter 9: Applications

Pave through the intersection with the Sonic Tracker in Automatic. Upon reaching the end of the intersection put the System Five Box back in Manual and change to slope control and survey the slope to get an On-grade signal.

Figure 9.04d

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Chapter 9: Applications

Figure 9.04e

Figure 9.04f

NOTICE You may find after surveying the slope that the number displayed is not the same as the desired cross slope. This will occur if the surface being paved is not also at the desired slope. To get back to the correct slope continue paving in automatic and slowly dial the display to the desired slope. Failing to survey when changing back to slope control could result in a bump in the mat. 9-14

System FiveTM Paver Operator's Manual

Chapter 10: Maintenance

Maintenance This section contains information regarding preventative maintenance and daily care of System FiveTM. Also included are:

1. Cleaning procedures for the Sonic Tracker IITM Transducer. 2. Replacement procedures for the Sonic Tracker IITM Transducer.

Preventative Maintenance & Daily Care A good preventative maintenance and daily care routine will prevent many problems before they occur. The most important part of daily care for System FiveTM is to clean it and keep it free of debris, and to thoroughly dry removable components (Sonic Tracker IITM, the Control Box, and cables) before storing them in the Carrying Case. In addition, the following procedures will ensure trouble free operation: 1. Keep the Carrying Case clean and dry. Do not leave it open and exposed to the elements. Clean and dry all components prior to placing them into the Carrying Case. 2. Be sure cables left on the paver are attached to protective connector caps, not in use. Water accumulating on the connectors can cause electrical shorts. System FiveTM Paver Operator's Manual

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Chapter 10: Maintenance

3. Do not use high pressure spray water steam cleaner hoses directly on cables and components. The components can be used in the rain or light spraying. 4. Check the Sonic Tracker IITM Transducer daily to make sure the Filter Foam and Transducer are clean and free of debris. If the Filter Foam is clogged with dirt, replace it. If the Transducer appears to be covered with debris and performance is being affected (see Sonic Tracker IITM in Chapter 2: Operation) clean or replace Sonic Tracker IITM Transducer using the steps listed later in this chapter.

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Chapter 10: Maintenance

Transducer Cleaning (Sonic Tracker II) NOTICE This procedure is not meant to be a regular maintenance procedure. Cleaning of the Transducer should only be performed when Transducer contamination is suspected or evident. Over cleaning of the transducer will result in shortened Transducer life and/or water damage to the Sonic Tracker. 1. Hold the Sonic Tracker IITM in an UPRIGHT position (this will prevent moisture from inadvertently entering the Sonic Tracker). 2. Mix a mild detergent with water and place the mixture in a spray bottle (use Simple Green® where available.) 3. With the Sonic Tracker IITM upright, thoroughly spray the Transducer with the detergent solution. 4. Once the Transducer has been sprayed with the detergent, fill the spray bottle with clean water and rinse any residual detergent off of the Transducer. 5. Allow to thoroughly dry. If the ability of the Sonic Tracker IITM to "see" a sonic stringline continues to be impaired, the transducer may be damaged and needs replaced. 10-3

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Chapter 10: Maintenance

Transducer Replacement Procedure (Sonic Tracker II) NOTICE If the Sonic Tracker II is experiencing erratic or inconsistent readings, Transducer contamination should be considered first before assuming any other type of failure. The most common sign of Transducer contamination is the ability of the Sonic Tracker IITM to “see” the ground, but not a Sonic Stringline.

Sonic Tracker II Transducer Replacement 1. Remove and discard the Filter Foam (a new Filter Foam is provided in the Transducer Replacement Kit). Figure 10.01a

10-4

2. Remove the four screws and the black Retaining Ring. There are four replacement screws supplied in the Transducer Replacement Kit, but it is advisable to use the original screws and keep the four supplied in the kit for replacements in the event one or more are lost). Remove and discard the “O”-Ring (a new “O”-Ring is supplied with the Transducer Replacement kit). Figure 10.01b System FiveTM Paver Operator's Manual

Chapter 10: Maintenance

NOTICE Always remove and discard used “O”-Rings. Used “O”-Rings will be distorted and may loose there elasticity due to weather or exposure to diesel fumes. 3. The Transducer can now be gently pulled out. Use a SMALL pair of dikes to gently cut the Ty-Wrap then remove the small wire connectors from their tabs. NOTICE When cutting the Ty-Wrap, be careful not to cut or damage the wires.

Figure 10.01c

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System FiveTM Paver Operator's Manual

Chapter 10: Maintenance

4. Place the wire connectors of the new Transducer firmly on their tabs (the gray wire connector is placed on the elevated tab). Place the Ty-Wrap in the slot next to the elevated (gray wire) tab, tighten and trim. DO NOT pinch the wires.

Figure 10.01d

5. "Feed" the wires back up into the Sonic Tracker IITM and seat the Transducer into place (the two wire tabs have to sit down into the extra deep area of the recess). Place the new “O”-ring around the Transducer and seat firmly between the Transducer and the Sonic Tracker IITM Transducer recess.

Figure 10.01e

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Chapter 10: Maintenance

6. Place the black Retaining Ring over the Transducer assembly with the beveled edges out and the flat surface against the Sonic Tracker IITM base. Line up the holes for the mounting screws (the mounting screw holes are set to an irregular pattern. This ensures the retaining ring will only lineup with the mounting holes one way). 7. Start the mounting screws into the holes and tighten each until firm. DO NOT OVER TIGHTEN. Use a cross (X) pattern to tighten screws.

Figure 10.01f

NOTICE Over tightening may distort the Transducer metallic material and may crack the Retaining Ring. Use of the “O”-Ring assures tightness while preventing vibration from loosening the Mounting Screws.

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Chapter 10: Maintenance

NOTICE DO NOT use Loctite® on the mounting screws. Loctite® will attack the plastic retaining ring. 8. Make sure there are no visible wrinkles in the metallic surface inside the Transducer. If distortion is evident, repeat Steps 5 through 8. 9. Place a NEW Filter Foam over the Transducer. The Sonic Tracker IITM is now ready to return to operation.

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System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

Troubleshooting Control Box Symptoms 1.

Control Box LCD does not Display

2.

Control Box LCD displays "Error"

3.

Cannot adjust to On-Grade when Elevation Control is selected.

4.

Tow point cylinder does not move Up or Down

5.

Tow point cylinder moves in the wrong direction

6.

Tow point cylinder moves too fast or too slow.

7.

System intermittently drives the cylinder all the way up or down when tracking a mechanical ski.

8.

Control Box displays Error and a number from 1 to 4

9.

Grade lights flash high and low and will not stay On-Grade.

10. The valve is driving the hydraulic cylinder too far overshooting grade. 11. The valve will not drive hydraulic cylinder far enough to get sensor On-Grade. 12. The Control Box displays "No Signal" when indicate is selected in elevation mode. 13. The Auto light on the Control Box intermittently flashes on and off.

System FiveTM Paver Operator's Manual

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Chapter 11: Troubleshooting

Control Box Symptom 1 •

"The Control Box LCD does not display."

Probable Cause • No power to the Control Box. 1. Check that the machine power is on and all switches for automatic control on the paver are in the proper position. 2. Check that all cables are properly and securely connected to the System Five™ Box and the paver. Make sure cables are not still connected to Control Box bracket. 3. Disconnect cables and inspect them for damage or contamination. Clean all connections with an electrical contact cleaner. NOTICE Do not use electrical contact cleaner to clean the Tracker's transducer. 4. Swap Control Boxes from left to right side. 5. For System Four™ bypass Junction Box by plugging coil cord from paver to J-Box directly into Control Box.

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Chapter 11: Troubleshooting

Control Box Symptom 2 •

"Control Box LCD shows 'Error '"

Figure 11.0

Probable Cause • No communication with the sensor selected. 1. Check that all cables are properly connected to System Five™ Control Box and sensors. 2. Disconnect cables and inspect them for damage or contamination. Clean all connections with an electrical contact cleaner. NOTICE Do not use electrical contact cleaner to clean the Tracker's Transducer. 3. If elevation has been selected, one at a time, swap the Sonic Tracker II™ and cables from the opposite side to locate the error.

System FiveTM Paver Operator's Manual

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Chapter 11: Troubleshooting

4. Refer to Tracker Symptom #1. 5. If slope has been selected, check that slope has not been selected on the other Control Box. Only one box at a time can have slope turned on. 6. Swap slope cable from opposite side. 7. Disconnect cable at slope sensor and connect to other side of sensor to check slope sensor pins.

Control Box Symptom 3 •

"Cannot adjust to On-Grade when elevation control is selected."

Probable Cause • Tracker is too close to control reference. 1. Check that the Sonic Tracker II™ is at least 14 inches away from the control reference. 2. Check for unwanted objects within the sonic footprint. 3. Make sure tracker is not positioned in front of a gusty heat source, such as the engine fan exhaust.

11-4

4. Stop the paver, make sure the screed is on the ground and turn the vibrators off. Press Survey and hold for 2 seconds. "IND" will display on the faceplate and a number will be displayed on the LCD. The number should stay constant, or change up and down by a few numbers. If the numbers fluctuate significantly then the Transducer is probably weak or damaged.

System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

5. Check for contamination on the Sonic Tracker II™ Transducer or foam filter. Refer to Transducer and Filter Cleaning and replacement information in the Maintenance and Parts section of this manual. 6. Swap the Tracker with the unit on the opposite side. 7. Averaging may be set too low if tracking an uneven reference. Factory setting is 50.

Control Box Symptom 4 •

"The tow point cylinder doesn't move up or down."

Probable Cause • Machine electrical switches are not in the proper position, or hydraulics to the cylinder are not active. 1. Check that all locking pins have been removed and that all hydraulic blocking valves are in the open and correct position for automatic control. Refer to the paver manufacturer's manual. 2. Check that all machine electrical switches and in motion circuits are in the correct position for automatic control. Refer to the paver manufacturers manual. Press the jog switch up and down on the Control Box to make sure there is a current going to the valve. Cylinder should move in the same direction the jog switch is pressed. 3. Check that the Auto Switch is in "Auto" and that the Auto Symbol is illuminated on the front panel.

System FiveTM Paver Operator's Manual

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Chapter 11: Troubleshooting

4. Disconnect cables and inspect them for damage or contamination. Clean all connections with an electrical contact cleaner. 5. Swap the Control Box with the unit on the opposite side. 6. If a Control Box is replaced make sure the configuration and performance settings are correct. 7. If a cable is replaced make sure it is the right part number. A cable with the incorrect resistor could set the Control Box to have the wrong configuration.

Control Box Symptom 5 • "The tow point cylinder is moving in the wrong direction." Probable Cause

• Machine is incorrectly wired or hydraulically connected. 1. Check that the machine is properly wired and hydraulically connected to the valve. A raised jog switch should make the cylinder go up, lowering the jog switch should make the cylinder go down. 2. Check that the proper cables have been supplied for your machine. 3. For System Four, if "OIN" setting is in the performance menu, make sure it is in the off position. 11-6

4. Make sure the screed lift cylinders are in the float position and not supporting the screed. System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

Control Box Symptom 6 • "The tow point cylinder is moving 'too fast' or 'too slow." Probable Cause • The paving machine's hydraulic flow

adjustment is incorrect, or the control box Valve Offsets or Gain Adjustments are not correct. 1. Refer to paver manufacturers recommended flow adjustment setting for the time it takes the hydraulic cylinder to complete a full stroke of travel. Typically between 12 to 15 seconds. 2. Adjust Gain Performance Settings. Factory setting is 25. 3. Adjust Valve Offsets. Refer to Valve Offset section in the Performance Section within this Manual.

Control Box Symptom 7 • "System intermittently drives the cylinder all the way up or down when tracking a mechanical ski." Probable Cause • Tracker is intermittently picking up signals from the ski. 1. Verify string is at least 4 inches above the surface of the ski. Ski will pull away from the paver and can get in Tracker's Working Window if string is too close. Ski will also tilt to one side when traveling through a super elevation or slope transition.

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Chapter 11: Troubleshooting

2. For a multi-foot ski, make sure "foot spring pin" is not within the sonic footprint as the ski surges back and forth.

Control Box Symptom 8 • "Control Box displays Error and a number from 1-4" Probable Cause • Defective Sonic Tracker or SAS cable. 1. Check SAS cable connections at each tracker. 2. Turn Control Box off and swap tracker showing the error number (1-4) with another tracker on the SAS. (Tracker number is on the cable at the tracker connector). Turn Control Box on to reset SAS. If the error number (1-4) has changed, the problem is the tracker. If the error number remains the same, the problem is the SAS cable. 3. If more than one error number is shown, check trackers individually by plugging sonic trackers directly into the single tracker coil cord to determine if trackers or SAS cable is source of error. 4. The defective tracker or SAS cable should be repaired, but SAS can still be operated without all four. Remember balance point will change if a tracker is removed.

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Chapter 11: Troubleshooting

Control Box Symptom 9 • "Grade lights flash high and low and will not stay on grade." Probable Cause • If problem is only in automatic mode, then hydraulic Performance Settings are incorrect. 1. Verify paving machines hydraulic flow adjustments (time for hydraulic cylinder to travel full stroke) are set to manufactures recommendations. 2. Check that the Valve Offsets are set correctly. 3. Check that the Gain setting is too high. Factory setting is 25. •

If problem is in manual mode, then

1. Verify that temperature bails are clean and securely attached. 2. Verify temperature bail symbol "T" is displayed on face of Tracker. If not clean or replace transducer. 3. Check that Trackers are between 14 and 24 inches from reference. 4. If there are gusty winds, lower Tracker closer to reference. Approximately 14 to 16 inches. 5. Move Tracker away from gusty heat source, such as engine fan exhaust. 6. Verify Tracker is not picking up erroneous signals from undesired reference. Example: Head of material, end gate, shoulder grade or material spillage from hopper.

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Chapter 11: Troubleshooting

7. If using Stringline, verify line is not bouncing. 8. Check to see if Averaging in Performance Menu is set too low. Factory setting is 50. 9. Check Deadband in Performance Menu is not less than 3mm.

Control Box Symptom 10 • "The valve is driving the hydraulic cylinder too far, overshooting grade." Probable Cause • Valve Offset in Control Box are set too high. 1. Lower the Valve Offset value till the sensor no longer overshoots grade. Refer to "Setting Valve Offsets" section in this manual. 2. For Servo and solenoid valves lower the value by 2 to 5 numbers, then check the hydraulic performance. 3. For Proportional valves, lower the value by 10 to 15 numbers, then check hydraulic performances.

Control Box Symptom 11 • "The valve will not drive hydraulic cylinder far enough to get sensor On-Grade." Probable Cause • Valve offsets in Control Box are set too low. 1. Raise the Valve Offset Value till the sensor is driven to grade. Refer to "Setting Valve Offsets" section in this Manual. 11-10

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Chapter 11: Troubleshooting

2. For Servo and Solenoid valves raise the value by 2 to 5 numbers, then check hydraulic performance. 3. For Proportional valves raise the value by 10 to 15 numbers, then check hydraulic performance.

Control Box Symptom 12 • "The Control Box displays 'No Signal' when indicate is selected in elevation mode." Probable Cause • Sonic Tracker is reporting no echo. 1. Verify that the Sonic Tracker is ticking. 2. Make sure tracker is pointing at a target with the working range, recommended 14 to 24 inches. 3. Transducer may be dirty or damaged. Refer to the Transducer and Filter section within this manual. 4. Power or ground connection at transducer may be loose. Remove transducer and check wires.

11-11

System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

Control Box Symptom 13 • "The Auto light on the Control Box intermittently flashes on and off." Probable Cause • Sonic Tracker is too far from reference for current atmospheric conditions, or Temperature Cutout is too low. 1. Verify that the Sonic Tracker is positioned 14 to 24 inches from the reference. If there are gusty winds lower the Tracker to 14 to 16 inches from the reference. 2. Move Tracker away from gusty heat source, such as engine fan exhaust. 3. Temperature Cutout is set too low. Factory setting is 7. Refer to Technicians manual.

11-12

System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

Tracker Symptoms 1.

Sonic Tracker will not power on.

2.

Sonic Tracker is ticking, but will not adjust to Grade

3.

Tracker grade lights flash high and low and will not stay On-Grade.

4.

Sonic Tracker is not matching joint or curb.

5.

The Sonic Tracker will pick up the ground, but will not pick up a stringline.

Tracker Symptom 1 • "Sonic Tracker will not power on" Probable Cause • Defective cable or tracker. 1. Check coil cord is plugged in correctly and securely. 2. Inspect Coil cord for any physical damage. 3. Turn Control Box on and watch the tracker lights to make sure they go through the power up sequence. All the lights on the tracker should flash at once followed by a flash of an arrow pointing to the left. The "T" symbol should also be displayed in the upper right hand corner of the tracker faceplate when a Temperature Bail is attached. If the tracker does not go through this sequence then the tracker is not getting power or is defective. 4. One at a time, swap tracker and then coil cord from opposite side to determine the problem. System FiveTM Paver Operator's Manual

11-13

Chapter 11: Troubleshooting

Tracker Symptom 2 • "Sonic Tracker is ticking, but will not adjust to grade." Probable Cause • Tracker is too close to reference, minimum working distance is 14 inches. 1. Tracker is too close to reference point. Position tracker 14 to 24 inches from grade reference. 2. Connect tracker to other side of paver to determine if problem stays with tracker. 3. If problem stays with tracker, clean or replace transducer or foam filter. Refer to the Transducer and filter cleaning and replacement information in the "Maintenance and Parts" section of this manual. 4. If problem does not move with tracker, inspect coil cord for damage and swap with cord from other side.

Tracker Symptom 3 • "Tracker grade lights flash high and low and will not stay On-Grade." Probable Cause • If problem is only in Automatic Mode, then Hydraulic Performance Settings are incorrect.

11-14

1. Verify paving machines hydraulic flow adjustments, time for hydraulic cylinder to travel full stroke, are set to manufacturers recommendations. Typically 12 to 15 seconds.

System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

2. Check Valve Offsets are set correctly. Refer to setting valve offsets. 3. Make sure Gain Setting is not too high. Factory setting is 25. •

If problem exists in manual mode, then Tracker is setup incorrectly or Performance Settings are incorrect.

1. Verify that temperature bails are clean and securely attached. 2. Verify temperature bail symbol "T" is dis played on face of Tracker. If not, clean or replace transducer. 3. Check that Trackers are between 14 and 24 inches from reference. 4. If there are gusty winds, lower Tracker closer to reference. Approximately 14 to 16 inches. 5. Move Tracker away from gusty heat source, such as engine fan exhaust. 6. Verify Tracker is not picking up erroneous signals from undesired reference. Example: Head of material, end gate, shoulder grade or material spillage from hopper. 7. If using Stringline, verify line is not bouncing. 8. Check to see if Averaging in Performance Menu is set too low. Factory setting is 50. 11-15

System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

9. Check that Deadband, in Performance Menu, is not less than 3mm.

Tracker Symptom 4 • "The Sonic Tracker is not matching joint or curb." Probable Cause • Tracker is too far forward on the tow arm. 1. Position the Tracker at 1/3rd the tow arm length (just in front of auger). 2. Gain for tracker may be set too low. Adjust Gain to a minimum of 25. 3. Brackets and L-Bars have not been securely tightened. Also, check for excessive play or slop where tracker is attached to the paver. (Tow arm or end gate.)

Tracker Symptom 5 • "The Sonic Tracker will pick up the ground, but will not pick up a stringline." Probable Cause • Tracker is too close to a reference or transducer is weak. 1. Verify that tracker is at least 14" from the stringline. 2. Smooth, steel wire is not recommended. Use minimum 1/16" diameter string for elevated stringline or averaging ski. Use 1/8" string for Surface Stringline.

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System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

Slope Sensor Symptoms 1. Cross Slope reads "Error" 2. Cross slope drives cylinder in the wrong direction 3. Slope lights flash between raise and lower and will not stay On-Grade. 4. Cross slope will not lock On-Grade. 5. Cross slope being laid is not correct.

Slope Sensor Symptom 1 • "Cross Slope reads 'Error." Probable Cause • Both Control Boxes are selected for slope or have a defective cable. 1. Cross slope operates one side at a time. Verify only one Control Box has been selected for slope. 2. Verify that the slope cable is connected securely and properly. 3. Swap slope cable from other side to check cable.

11-17

System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

Slope Sensor Symptom 2 • "Cross Slope drives cylinder in the wrong direction." Probable Cause • Slope sensor installed incorrectly. 1. Verify the slope sensor is positioned correctly on the transverse beam. "Slope Forward" Decal must be in direction of travel. 2. Check that the machine is properly wired and hydraulically connected to the valve. Raised jog switch should make the cylinder go up, lower jog switch should make the cylinder go down. Refer to the paver manufacturers manual.

Slope Sensor Symptom 3 • "Slope lights flash between raise and lower and will not stay On-Grade." Probable Cause • Incorrect Performance Setting adjustments or a loose transverse beam. 1. Check Valve Offset for proper operation. Refer to "Setting Valve Offsets" section in this manual. 2. Check gain setting. Factory setting is 25. 3. Slope deadband set too low. Increase Slope Deadband. Factory Setting is .075% 4. Check for excess vibration in the Transverse Beam due to poor connection at Tow Arm. 11-18

5. Make sure slope sensor is mounted directly to the Transverse Beam and is not elevated or supported by additional brackets. System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

Slope Sensor Symptom 4 • "Cross Slope will not lock On-Grade." Probable Cause • Loose Transverse Beam or incorrect Performance Setting adjustments. 1. Verify that the Slope Sensor is not moving or vibrating when trying to survey slope on grade. 2. Slope deadband setting is too low, factory setting is .075%. 3. Stop the paver, make sure the screed is on the ground and turn the vibrators off. Press Survey and hold for 2 seconds. IND will display on the faceplate and a slope value will appear in the LCD. The number should stay constant or change up or down by a few counts. If the numbers fluctuate significantly then the slope sensor is probably the problem.

Slope Sensor Symptom 5 • "The Cross Slope being laid is not correct." Probable Cause • Calibration in Slope Sensor is incorrect. 1. Calibrate the Slope Sensor as described in “Daily Cross Slope Calibration” in the Function and Operations section. 2. Check that the Transverse Beam is mounted according to the manufacturer’s instructions and that it is not loose or damaged.

System FiveTM Paver Operator's Manual

11-19

Chapter 11: Troubleshooting

3. Recheck slope using a good reference such as a laser or level. Make sure to wait at least 3 tow arm lengths before checking the slope after a change has been made. 4. If the paver's mat thickness controls have been used then the slope calibration may have to be changed. This can occur after "buying back" cylinder.

11-20

System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

SAS Symptoms 1. When the SAS is connected, control Box displays "Error" and a number. 2. 1 Tracker stops working 3. SAS will not lock On-Grade 4. SAS is not producing smooth surface 5. Tracker picking up head of material

SAS Symptom 1 • "When the SAS is connected, the Control Box displays 'Error' and a number." Probable Cause • Defective tracker or cable, tracker with incorrect code. 1. Verify that all trackers are correctly and securely plugged into the SAS cable. 2. Turn Control Box off and move the Tracker to a different position on the SAS cable. Turn the Control Box on to reconfigure SAS. If error number moved positions with the swapped tracker, then the tracker is the problem. Replace transducer if necessary. Refer to transducer and filter cleaning and replacement information in the "Maintenance and Parts" section of this manual.

11-21

System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

3. Check to see if a Tracker without SAS code is attached to the cable. Verify that the tracker has a SAS compatible decal near the S/N label.

Figure 11.01a

4. Tracker can also be checked by verifying code revision. Turn box off and back on. Watch the temperature bail symbol in the top right portion of the tracker. The "T" symbol will flash a certain number of times, pause and flash again to indicate the revision of its code.

Figure 11.01b

11-22

Example: Flash twice, pause flash twice means the code in the Tracker is 2.2. SAS requires trackers with code of 2.2 or higher. System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

SAS Symptom 2 • "A Tracker stops working." Probable Cause • Defective Tracker. 1. Check SAS cable connections at each tracker. 2. Turn off Control Box and swap tracker showing error with another tracker on the SAS. (Tracker number is on the cable at the tracker connector). Turn the Control Box back on to reset SAS. If error number moved positions with the swapped tracker, then the tracker is the problem. Replace transducer if necessary. Refer to Transducer and Filter Cleaning and Replacement information in the "Maintenance and Parts" section of this manual. 3. If error continues to display for the same position even after trackers have been swapped, the tracker connector or SAS cable is the problem. 4. The defective tracker or SAS cable should be repaired, but SAS can still be operated without all four trackers operating. Remember balance point will change if a tracker is removed.

11-23

System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

SAS Symptom 3 • "SAS will not lock on grade." Probable Cause • Tracker too close to reference or defective transducer in Tracker. 1. Verify that all cable connections are properly and securely connected. 2. Check that all trackers are sending out sound waves (transducer is making ticking sound) and grade lights are flashing. 3. If tracker is not working, check that transducer and foam filter are clean and free from damage. Replace transducer if necessary. Refer to transducer and filter cleaning and replacement information in the "Maintenance and Parts" section of this manual. 4. SAS beam and trackers may be too close to reference. Bottom of tracker must be minimum of 14 inches from reference. 5. Non-SAS compatible tracker attached to cable. Verify tracker has SAS compatible decal near S/N label.

11-24 Figure 11.02

System FiveTM Paver Operator's Manual

Chapter 11: Troubleshooting

SAS Symptom 4 • "SAS is not producing smooth surface." Probable Cause • Improper setup or Performance Menu Settings. 1. Verify that temperature bails are clean and securely attached. 2. Verify temperature bail symbol "T" is displayed on face of Tracker. If not clean or replace transducer. Refer to transducer and filter cleaning and replacement information in the "Maintenance and Parts" section of this manual. 3. Check that Trackers are between 14 and 24 inches from reference. 4. If there are gusty winds, lower SAS to get Trackers closer to reference. 5. Move the Tracker away from gusty heat source, such as engine fan exhaust. 6. Verify that the Trackers are not picking up erroneous signals from undesired reference. Example:

Head of material, end gate shoulder grade or material spillage from hopper.

7. Verify that the center of the SAS beam is between the midpoint and the forward 2/3 point of the tow arm. 8. Check to see if Averaging in Performance Menu is set too low. Factory setting is 50. 9. Check that Deadband in Performance Menu is not less than 3mm. System FiveTM Paver Operator's Manual

11-25

Chapter 11: Troubleshooting

10. Check that Valve Offsets are set properly. 11. Check that the Gain setting in the Performance Menu is not set too high. Factory setting is 25.

SAS Symptom 5 • "Tracker picking up head of material." Probable Cause • Improper placement of Tracker 1. Move tracker forward of the material. Rotate Tracker to front of bracket or drill a hole in the beam far enough forward to move tracker away from material. 2. Check balance point. Balance point will shift when moving a tracker.

11-26

System FiveTM Paver Operator's Manual

Appendix

Appendix A Aggregate

Various hard, inert materials such as sand, gravel, pebbles, etc. used as the bulk material in asphaltic mixes. Angle of Attack

The angle that exists between the bottom of the screed and the grade over which the screed is traveling. Auger

The broad, spiral flange on a screed which rotates and spreads paving material evenly in front of the screed. Auger Shadows

The dark and light areas along the length of a mat surface caused by the compaction of materials having different densities and textures. Automatic Feed Controls

The dual feed system on a paving machine used to maintain a constant head of material in front of the screed. Automatic Grade and Slope Controls

Sensing equipment used on paving machines to set and maintain proper elevations and percent slope. Paver Control System FiveTM provides paver operators with automatic grade and slope control.

System FiveTM Paver Operator's Manual

A-1

Appendix

B Bitumen

A thick, viscous, petroleum-based substance used as a bonding agent in asphaltic mixes. Bail

A wire frame added to the Tracker that acts as a fixed target to compensate for rapid air temperature changes.

C Calibration

Setting the elevation reading or Slope Sensor reading to match the actual position of the screed. Compaction

To press tightly, thereby increasing the density of paving material. Cone

Pattern of distribution of the Sonic Tracker IITM sound waves. The sound waves leave the Tracker in a circular pattern that gets wider as it gets further from the Tracker. Conveyor

The assembly used to move paving material from the hopper to the auger. Cross Slope

The angle of slope required to produce a desired surface slope. Cross slope is measured in percent. Cross Slope

A-2

The angle of slope required to produce a desired surface slope. Cross slope is measured in percent.

System FiveTM Paver Operator's Manual

Appendix Crown

1. The transverse contour of a finished mat. 2. The contour of the screed plate. 3. The transition line between 2 different slopes (i.e. between lanes or between lanes and shoulders). Lead Crown

The contour or profile from side to side of the leading edge of the screed. Tail (Road) Crown

The contour of the trailing edge of the screed. Negative Crown

Contour which is higher at the edges than at the center of a mat. Positive Crown

Contour which is higher at the center than at the edges of a mat. Cut-off Shoe

A detachable plate used to reduce the paving width of a screed.

D Density

Compactness of paving material.

E Edger Plate

A vertical plate at each end of the screed used to con fine the head of material. Elevation

The vertical height or depth of the surface being laid. Elevation is measured in centimeters, inches, or feet. A-3

System FiveTM Paver Operator's Manual

Appendix

F Feeders

The auger-conveyors on the right and left hand sides of a paving machine.

G Grade

1. The base surface (road bed) over which paving is being laid. 2. The elevation of a fresh mat in relation to the base. 3. The incline of a paving surface in the direction of travel, expressed by stating the rise or fall as a percent age of horizontal distance (i.e., 6% grade = 6' of elevation change in 100' of horizontal longitudinal run). Grade Control

A means of controlling the elevation of a mat as it is being laid. Grade Sensor

An electric device which detects positive and negative changes in elevation from a grade reference (i.e., surface string, floating beam, mat reference, adjacent mat or curb surface).

H Head of Material

The volume of paving material directly in front of and across the entire length of the screed. Hopper

A-4

The area at the front of the paving machine which receives the paving material.

System FiveTM Paver Operator's Manual

Appendix Hydraulic

Liquid in motion under pressure, the flow of which causes work to be accomplished. Hydrostatic Transmission

Power transmitted by a positive displacement pump through a liquid under pressure to a positive displacement motor.

I Inclinometer

See Slope Sensor

J Joint Matcher

See Automatic Level Control

L LCD

Liquid crystal display. LCD is used in the display window on the Control Box and Sonic Tracker IITM to show numbers and symbols for Paver Control System FiveTM functions. LED

Light Emitting Diode. These are the red lights seen on the faces of the Control Box, Sonic Tracker IITM and Laser Tracker. Line of Shear

The lateral line of contact in the paving material at the leading edge of the screed pre-strike-off where material divides to pass beneath the screed plate or moves upward along the face of the screed into the augured material for later placement. System FiveTM Paver Operator's Manual

A-5

Appendix

M Mat

The material being placed by a paver/finisher

N Null

A condition which exists when components are at rest. "Null" Screed

A screed resting flat on the mat and having no angle of attack.

O On Grade

When a surface is at the desired elevation or slope, it is referred to as being on grade. Overlay

Paving over an existing mat.

P Paddle Box

The sensing device used with automatic feed control to measure and control the head of material. Percent (%) Slope

The unit of measure used for cross slope. Pull Points

See Tow Points A-6

System FiveTM Paver Operator's Manual

Appendix Push Roller

Rollers mounted at the front of the paver to control the contact area between he paver and the asphalt truck tires.

Q Quarter Points

Points on the screed midway between the center and the ends.

R Ripples

Short frequent changes in the elevation of a mat sur face.

S Screed

The assembly behind the tractor. The screed strikes off, smooths and compacts the paving material into a semifinished mat. Screed Extensions

Attachments for increasing screed width Screed Heaters (Burners)

Devices which preheat the screed plate to a temperature approximately that of the material to be laid. Screed Plate

The bottom plate of the screed

A-7

System FiveTM Paver Operator's Manual

Appendix Slope

The incline of a paving surface perpendicular to the direction of travel expressed by stating the rise or fall of a percentage of horizontal distance (i.e. 2% slope = 2" of elevation change in 100" of lateral run). Slope Control

A means for controlling the transverse elevation of the fresh laid mat in relation to the grade. Slope

The incline of a paving surface perpendicular to the direction of travel expressed by stating the rise or fall of a percentage of horizontal distance (i.e. 2% slope = 2" of elevation change in 100" of lateral run). Slope Control

A means for controlling the transverse elevation of the fresh laid mat in relation to the grade.

Q Slope Sensor

An electrical device which detects positive and negative change in lateral elevation using the grade controlled side of the machine as a reference. Survey

Function used to show the current elevation when in CAL mode. Also used in Laser Tracker operations in conjunction with he Enter Button to move the Tracker receiver up and down.

T Thickness Control Screws

A-8

The adjusting crank located at the rear of each side arm, used to control the angle of attack of the screed. System FiveTM Paver Operator's Manual

Appendix Tow Points (Pull Points)

The points where the side arms of the screed are attached to the Tractor unit. Transverse Beam

A steel bar connected to the side arms of a screed for mounting the Slope Sensor. Temperature BailTM

A wire frame added to the Tracker that acts as a fixed target to compensate for rapid air temperature changes..

V Vibrators

A rotating shaft and eccentric weight assembly mounted on the screed that produces vibration.

W Wave

Long repeating changes in the elevation of the mat surface. Working Window

Adjustable region of measurement used by the Sonic Tracker IITM to determine if elevation correction is required.

A-9

System FiveTM Paver Operator's Manual

PAVER TECHNICAL MANUAL

Schematics Section

Table of Contents Schematics Section REFERENCE FORMS Electrical & Hydraulic Schematics Cross Reference ............................................... Form 22767 Electrical Test Plug (used for operating paver feed sys. w/o screed) ....................... Form 22204 Standard Graphical Symbols ................................................................................. Form 21707 SCHEMATICS CR551 - Electrical .................................................................................................. 4418-547 CR561 - Electrical .................................................................................................. 4418-585 CR451 - Electrical .................................................................................................. 4418-631 CR461 - Electrcial .................................................................................................. 4418-632 Stretch 20 Screed - Hydraulic .................................................................................. 4418-638 Fastach 10' Std. Screed - Hydraulic ......................................................................... 4418-639 CR461 - Hydraulic .................................................................................................. 4418-642 CR451 - Hydraulic .................................................................................................. 4418-643 CR451 - Electrical ................................................................................................... 4418-663 CR461 - Electrical ................................................................................................... 4418-664 CR351 - Hydraulic .................................................................................................. 4418-671 CR361 - Hydraulic .................................................................................................. 4418-672 CR351 - Electrical ................................................................................................... 4418-682 CR361 - Electrical ................................................................................................... 4418-683 CR551 - Hydraulic .................................................................................................. 4418-687 CR561 - Hydraulic .................................................................................................. 4418-688 Fastach 10' Screed - Hydraulic ................................................................................ 4418-698 Fastach 8' Screed - Hydraulic .................................................................................. 4418-703 CR461 - Electrical ................................................................................................... 4418-724 CR451 - Electrical ................................................................................................... 4418-725 CR451 - Hydraulic .................................................................................................. 4418-727 CR461 - Hydraulic .................................................................................................. 4418-728 Fastach 10' Screed with EZ Screed II - Hydraulic .................................................... 4418-748 CR451 w/ Steer Assist - Electrical ........................................................................... 4418-771 MS-1, MS-2, MS-3 - Electrical .............................................................................. 4418-772 Fastach 8' Screed with EZ Screed II - Hydraulic ...................................................... 4418-773 CR411 - Hydraulic .................................................................................................. 4418-793 CR361 - Electrical ................................................................................................... 4418-798

Schematics

i

22484 (12/04)

Table of Contents Schematics Section SCHEMATICS - CONT CR351/411 - Electrical ............................................................................................ CR451/551 w/Servo - Hydraulic ............................................................................. CR461/561 - Hydraulic ........................................................................................... Stretch 18 Screed - Hydraulic .................................................................................. CR461/561 - Electrical ............................................................................................ CR551 w/ Servo - Electrical .................................................................................... Stretch 16 Screed - Hydraulic .................................................................................. MS-1 & MS-2 - Hydraulic ...................................................................................... MS-3 - Hydraulic .................................................................................................... CR461/561 - Hydraulic ........................................................................................... CR361/461/561 Slat - Electrical .............................................................................. CR351/411/451/551 Slat - Electrical ....................................................................... Fastach 8 w/Vibratory Strike-Off - Hydraulic ........................................................... Grayhound Pavers - Electrical .................................................................................. CR351/451/551 Slat - Electrical (Current Production) ............................................. CR361/461/561 Slat - Electrical (Current Production) ............................................. CR351 - Hydraulic (Current Production) ................................................................. CR361 - Hydraulic (Current Production) ................................................................. CR451/551 Slat - Hydraulic (Current Production) .................................................... CR461/561 Slat - Hydraulic (Current Production) .................................................... CR461/561 Slat, Rubber Track - Hydraulic ............................................................. CR361 Rubber Track - Hydraulic ............................................................................ CR351/451/551 Gen III Standard - Electrical .......................................................... CR361/461/561 Gen III Standard - Electrical .......................................................... CR351/451/551 Remix - Electrical .......................................................................... CR361/461/561 Remix - Electrical .......................................................................... CR351 Gen III Standard - Electrical ........................................................................ CR361 Gen III Standard - Electrical ........................................................................ Rubber Tire Paver - Convert to Slat from Remix - Electrical ..................................... CR361/461/561 w/Dual Joysticks, Gen III Standard - Electrical .............................. CR451/551 Slat, Rubber Tire - Hydraulic ................................................................ CR461/561 Slat, Steel Track - Hydraulic ................................................................. CR461/561 Slat, Rubber Track - Hydraulic ............................................................

Schematics

ii

4418-799 4418-808 4418-809 4418-810 4418-815 4418-816 4418-818 4418-831 4418-832 4418-861 4418-864 4418-865 4418-867 4418-923 4418-937 4418-938 4418-944 4418-945 4418-946 4418-947 4418-952 4418-956 4418-959 4418-960 4418-963 4418-964 4418-973 4418-974 4418-978 4418-994 4418-995 4418-996 4418-997

22484 (12/04)

Table of Contents Schematics Section SCHEMATICS - CONT 352 Slat Pavers - Tier II - Electrical .................................................................... 4494-105-19 362 Slat Pavers - Tier II - Electrical .................................................................... 4494-105-20 452/552 Slat Pavers - Tier II - Electrical ............................................................ 4494-105-21 462/562 Slat Pavers - Tier II - Electrical ............................................................. 4494-105-22 452/552 Remix Pavers - Tier II - Electrical ........................................................ 4494-105-23 462/562 Remix Pavers - Tier II - Electrical ......................................................... 4494-105-24 452/552 Remix Pavers - Tier II - Electrical (2004 update) ................................... 4494-105-29 462/562 Remix Pavers - Tier II - Electrical (2004 update) ................................... 4494-105-30 CR451/551 Remix Pavers - Hydraulic ..................................................................... 4495-001 CR461/561 Remix Pavers - Hydraulic ..................................................................... 4495-002 CR461/561 Remix Pavers, Rubber Track - Hydraulic .............................................. 4495-003 Stretch Screeds - Hydraulic ..................................................................................... 4495-004 Fixed Screeds - Hydraulic ....................................................................................... 4495-005 MS-4 - Hydraulic & Electrical ................................................................................. 4494-006 Stretch Electric Screeds - Hydraulic & Electrical ...................................................... 4495-007 400 & 500 Series Slat Pavers - Tier II - Hydraulic ................................................... 4495-008 400 & 500 Series Remix Pavers - Tier II - Hydraulic ............................................... 4495-009 Fastach II Screeds - Hydraulic & Electric (20kW Generator) .................................... 4495-011 300 Series Slat Pavers - Tier II - Hydraulic .............................................................. 4495-012 Fastach II Screeds - Hydraulic & Electric (34kW, 3PH Generator) ......................... 4495-013 400 & 500 Series Remix Pavers - Tier II - Hydraulic ............................................... 4495-014

Schematics

iii

22484 (12/04)

This Page Intentionally Left Blank

Schematics

iv

22484 (12/04)

Electrical Schematic Cross Reference Paver Tractors Control Panel - Digital Gauges

Control Panel - Analog Gauges (Early Version)

Control Panel - Analog Gauges (Version until late 1999)

Control Panel - Analog Gauges (Version 1999 - Current)

DIGITAL GAUGES CR551 Digital Gauge --------------------------------------------------------CR561 Digital Gauge --------------------------------------------------------CR451 Digital Gauge --------------------------------------------------------CR461 Digital Gauge --------------------------------------------------------CR451 Digital Gauge Murphy Shutdown -------------------------------CR461 Digital Gauge Murphy Shutdown -------------------------------CR351 Digital Gauge Murphy Shutdown -------------------------------CR361 Digital Gauge Murphy Shutdown --------------------------------

ANALOG GAUGES - SLAT CR451/551 Analog Gauge, Murphy Shutdown Dual Headlights ----------------------------------------------------------------CR461/561 Analog Gauge, Murphy Shutdown Dual Headlights ----------------------------------------------------------------CR361 Analog Gauge, Murphy Shutdown -----------------------------CR351/411 Analog Gauge, Murphy Shutdown -----------------------Track Pavers with Steering Wheel, Permissive Start, No-Flow Lights -----------------------------------------Rubber Tired Pavers with Permissive Start, No-Flow Lights -----------------------------------------------------------------Track Pavers with Dual Sticks, Permissive Start, No-Flow Lights -----------------------------------------------------------------Rubber Tired Pavers with Permissive Start, No-Flow Lights, Elite Engine, Breakers and Main Switch in End of Main Box ------------------------------------------Track Pavers with Steering Wheel, Permissive Start, No-Flow Lights, Elite Engine, Breakers and Main Switch in End of Main Box -----------------------Rubber Tire Pavers, GEN III Standard ----------------------------------Track Pavers, GEN III Standard ------------------------------------------CR351, GEN III Standard ---------------------------------------------------CR361, GEN III Standard ---------------------------------------------------Rubber Tire Pavers, Convert to Slat from Remix --------------------Track Pavers w/Dual Joysticks, GEN III Standard -------------------CR361 Digital Gauge Murphy Shutdown ------------------------------352 Slat Pavers - Tier II -----------------------------------------------------362 Slat Pavers - Tier II -----------------------------------------------------452 & 552 Slat Pavers - Tier II --------------------------------------------462 & 562 Slat Pavers - Tier II ---------------------------------------------

ANALOG GAUGES - REMIX Rubber Tire Remix Pavers ------------------------------------------------Track Remix Pavers ---------------------------------------------------------452 & 552 Remix Pavers - Tier II ----------------------------------------462 & 562 Remix Pavers - Tier II ----------------------------------------452 & 552 Remix Pavers - Tier II (05/04) -----------------------------462 & 562 Remix Pavers - Tier II (05/04) ------------------------------

Schematics

1

4418-547 4418-585 4418-631 4418-632 4418-663 4418-664 4418-682 4418-683

4418-724 4418-725 4418-798 4418-799 4418-864 4418-865 4418-923

4418-937

4418-938 4418-959 4418-960 4418-973 4418-974 4418-978 4418-994 4418-683 4494-105-19 4494-105-20 4494-105-21 4494-105-22

4418-963 4418-964 4494-105-23 4494-105-24 4494-105-29 4494-105-30

22767 (12/04)

Hydraulic Schematic Cross Reference Paver Tractors PAVERS CR351 W/O FUME RECOVERY ----------------------------------------------------------------------------------------------------------------------------------- 4418-671 CR351 W/FUME RECOVERY --------------------------------------------------------------------------------------------------------------------------------------- 4418-944 CR361 STEEL TRACK, W/O FRAME RAISE ------------------------------------------------------------------------------------------------------------------- 4418-672 CR361 STEEL TRACK, W/FRAME RAISE, W/O FUME RECOVERY ----------------------------------------------------------------------------------- 9704-660-98 CR361 STEEL TRACK, W/FRAME RAISE, W/FUME RECOVERY -------------------------------------------------------------------------------------- 4418-945 CR361 RUBBER TRACK --------------------------------------------------------------------------------------------------------------------------------------------- 4418-956 300 SERIES SLAT PAVERS - TIER II ---------------------------------------------------------------------------------------------------------------------------- 4495-012 CR411 ---------------------------------------------------------------------------------------------------------------------------------------------------------------------- 4418-793 CR451 SLAT, SINGLE RESERVOIR ------------------------------------------------------------------------------------------------------------------------------ 4418-643 CR451 SLAT, DOUBLE RESERVOIR, W/O FUME RECOVERY ----------------------------------------------------------------------------------------- 4418-643 CR451 SLAT, DOUBLE RESERVOIR, W/FUME RECOVERY ------------------------------------------------------------------------------------------- 4418-946 CR461 CR461 CR461 CR461 CR461

SLAT, STEEL TRACK, SINGLE RESERVOIR ------------------------------------------------------------------------------------------------------- 4418-642 SLAT, STEEL TRACK, DOUBLE RESERVOIR, W/O FRAME RAISE ------------------------------------------------------------------------ 4418-728 SLAT, STEEL TRACK, DOUBLE RESERVOIR, W/FRAME RAISE, W/O FUME RECOVERY ----------------------------------------- 4418-728 SLAT, STEEL TRACK, DOUBLE RESERVOIR, W/FRAME RAISE, W/FUME RECOVERY ------------------------------------------- 4418-947 SLAT, RUBBER TRACK ----------------------------------------------------------------------------------------------------------------------------------- 4418-952

CR551 CR551 CR551 CR551

SLAT, HYD. TRAVEL CONTROL, W/O HYD. BRAKE PEDALS -------------------------------------------------------------------------------- 4418-687 SLAT, HYD. TRAVEL CONTROL, W/HYD. BRAKE PEDALS ----------------------------------------------------------------------------------- 9704-656-97 SLAT, ELEC. TRAVEL CONTROL, W/O FUME RECOVERY ----------------------------------------------------------------------------------- 4418-727 SLAT, ELEC. TRAVEL CONTROL, W/FUME RECOVERY ------------------------------------------------------------------------------------- 4418-946

CR561 CR561 CR561 CR561 CR561

SLAT, STEEL TRACK, HYD. TRAVEL CONTROL ------------------------------------------------------------------------------------------------- 4418-688 SLAT, STEEL TRACK, ELEC. TRAVEL CONTROL, W/O FRAME RAISE ------------------------------------------------------------------- 4418-728 SLAT, STEEL TRACK, ELEC. TRAVEL CONTROL, W/O FRAME RAISE, 8.2 ENGINE, SUNDSTRAND PUMPS -------------- 9704-659-45 SLAT, STEEL TRACK, ELEC. TRAVEL CONTROL, W/FRAME RAISE, W/O FUME RECOVERY ----------------------------------- 4418-861 SLAT, STEEL TRACK, ELEC. TRAVEL CONTROL, W/FRAME RAISE, W/FUME RECOVERY -------------------------------------- 4418-947

CR561 SLAT, RUBBER TRACK ----------------------------------------------------------------------------------------------------------------------------------- 4418-952 CR451/CR551 SLAT CONVEYOR, RUBBER TIRE PAVERS --------------------------------------------------------------------------------------------- 4418-995 CR451/CR551 SLAT CONVEYOR, STEEL TRACK PAVERS --------------------------------------------------------------------------------------------- 4418-996 CR451/CR551 SLAT CONVEYOR, RUBBER TRACK PAVERS ------------------------------------------------------------------------------------------ 4418-997 CR451/CR551 REMIX PAVERS ------------------------------------------------------------------------------------------------------------------------------------ 4495-001 CR461/CR561 REMIX, STEEL TRACK PAVERS ------------------------------------------------------------------------------------------------------------- 4495-002 CR461/CR561 REMIX, RUBBER TRACK PAVERS ---------------------------------------------------------------------------------------------------------- 4495-003 400 & 500 SERIES SLAT PAVERS - TIER II ------------------------------------------------------------------------------------------------------------------- 4495-008 400 & 500 SERIES REMIX PAVERS - TIER II ----------------------------------------------------------------------------------------------------------------- 4495-009 400 & 500 SERIES REMIX PAVERS - TIER II ----------------------------------------------------------------------------------------------------------------- 4495-014

Schematics

2

22767 (12/04)

Hydraulic & Electric Schematic Cross Reference Screeds SCREEDS 8' FASTACH W/O SLOPING STRIKE-OFF -------------------------------------------------------------------------------------------------------------------- 9704-658-78 8' FASTACH W/SLOPING STRIKE-OFF, W/O EZ-II -------------------------------------------------------------------------------------------------------- 4418-703 8' FASTACH W/SLOPING STRIKE-OFF, W/EZ-II ----------------------------------------------------------------------------------------------------------- 4418-867 10' FASTACH W/O EZ-II --------------------------------------------------------------------------------------------------------------------------------------------- 9704-657-40 10' FASTACH W/EZ-II ------------------------------------------------------------------------------------------------------------------------------------------------- 9704-658-80 STD. STRETCH 16 W/O SCREED ASSIST -------------------------------------------------------------------------------------------------------------------- 4418-818 STD. STRETCH 18 W/O SCREED ASSIST --------------------------------------------------------------------------------------------------------------------- 4418-810 STRETCH 16 & 18 W/SCREED ASSIST ------------------------------------------------------------------------------------------------------------------------- 9704-660-72 STRETCH 20 W/O SCREED ASSIST ---------------------------------------------------------------------------------------------------------------------------- 9704-657-41 10' EZ SCREED II ------------------------------------------------------------------------------------------------------------------------------------------------------ 4418-748 ALL STRETCH SCREEDS (Hydraulic Schematic) ----------------------------------------------------------------------------------------------------------- 4495-004 ALL FIXED SCREEDS (Hydraulic Schematic) ----------------------------------------------------------------------------------------------------------------- 4495-005 STRETCH ELECTRIC SCREEDS (Electric Schematic - used with 4495-004) ---------------------------------------------------------------------- 4495-007 FASTACH II SCREEDS, 20kW GENERATOR (Electric & Hydraulic Schematics) ----------------------------------------------------------------- 4495-011 FASTACH II SCREEDS, 34kW, 3PH GENERATOR (Electric & Hydraulic Schematics) ---------------------------------------------------------- 4495-013

Schematics

3

22767 (12/04)

Hydraulic & Electric Schematic Cross Reference MS Machines MS MACHINES MS-1, MS-2, MS-3 (Electric Schematic) ------------------------------------------------------------------------------------------------------------------------- 4418-772 MS-1 & MS-2 (Hydraulic Schematic) ----------------------------------------------------------------------------------------------------------------------------- 4418-831 MS-3 (Hydraulic Schematic) ---------------------------------------------------------------------------------------------------------------------------------------- 9702-050-43 MS-4 (Electric & Hydraulic Schematic) -------------------------------------------------------------------------------------------------------------------------- 4495-006

Schematics

4

22767 (12/04)

Technical Manual

Operating Paver Feed System Without Screed Attached &Electrical Test Plug To Operate Feed System on Tractor Without Screed Attached: Disconnect screed electrical cable from connector and install test plug P/N 9704-615-98 (shown below). Or... Disconnect screed electrical cable from connector. Open main electrical box (shown below) and install jumper wires at terminals as follows: ................... Wire 83 to 87 ................... Wire 93 to 97

Jumper Wires

Schematics

1

22484 (22204) (12/04)

Technical Manual

This Page Intentionally Left Blank

Schematics

2

22484 (22204) (12/04)

Standard Graphical Symbols T H E S Y M B O L S S H O W N C O N F O R M TO T H E A M E R I C A N N AT I O N A L S TA N D A R D S I N S T I T U T E ( A N S I ) SPECIFICATIONS. BASIC SYMBOLS CAN BE COMBINED IN ANY COMBINATION. NO ATTEMPT IS MADE TO SHOW ALL COMBINATIONS. LINES AND LINE FUNCTIONS

PUMPS

LINE, WORKING PUMP, SINGLE FIXED DISPLACEMENT LINE, PILOT (L>20W)

LINE, DRAIN (L<5W) PUMP, SINGLE VARIABLE DISPLACEMENT CONNECTOR

LINE, FLEXIBLE

MOTORS AND CYLINDERS

LINE, JOINING

MOTOR, ROTARY, FIXED DISPLACEMENT

LINE, PASSING

MOTOR, ROTARY, VARIABLE DISPLACEMENT

DIRECTION OF FLOW, HYDRAULIC PNEUMATIC

MOTOR, OSCILLATING

LINE TO RESERVOIR ABOVE FLUID LEVEL BELOW FLUID LEVEL

CYLINDER, SINGLE ACTING

LINE TO VENTED MANIFOLD

CYLINDER, DOUBLE ACTING

PLUG OR PLUGGED CONNECTION

CYLINDER, DIFFERENTIAL ROD

RESTRICTION, FIXED

CYLINDER, DOUBLE END ROD

RESTRICTION, VARIABLE

CYLINDER, CUSHIONS BOTH ENDS

Schematics

1

22484 (21707) (12/04)

MISCELLANEOUS UNITS

BASIC VALVE SYMBOLS (CONT.)

DIRECTION OF ROTATION (ARROW IN FRONT OF SHAFT)

VALVE, SINGLE FLOW PATH, NORMALLY OPEN

COMPONENT ENCLOSURE

VALVE, MAXIMUM PRESSURE (RELIEF)

RESERVOIR, VENTED

BASIC VALVE SYMBOL, MULTIPLE FLOW PATHS

RESERVOIR, PRESSURIZED

FLOW PATHS BLOCKED IN CENTER POSITION

PRESSURE GAUGE

MULTIPLE FLOW PATHS (ARROW SHOWS FLOW DIRECTION)

TEMPERATURE GAUGE

VALVE EXAMPLES UNLOADING VALVE, INTERNAL DRAIN, REMOTELY OPERATED

FLOW METER (FLOW RATE)

ELECTRIC MOTOR

DECELERATION VALVE, NORMALLY OPEN

M

ACCUMULATOR, SPRING LOADED

SEQUENCE VALVE, DIRECTLY OPERATED, EXTERNALLY DRAINED

ACCUMULATOR, GAS CHARGED

PRESSURE REDUCING VALVE

FILTER OR STRAINER COUNTER BALANCE VALVE WITH INTEGRAL CHECK

HEATER COOLER

TEMPERATURE AND PRESSURE COMPENSATED FLOW CONTROL WITH INTEGRAL CHECK

TEMPERATURE CONTROLLER INTENSIFIER PRESSURE SWITCH

DIRECTIONAL VALVE, TWO POSITION, THREE CONNECTION

BASIC VALVE SYMBOLS CHECK VALVE

DIRECTIONAL VALVE, THREE POSITION, FOUR CONNECTION

MANUAL SHUT OFF VALVE BASIC VALVE ENVELOPE

VALVE, INFINITE POSITIONING (INDICATED BY HORIZONTAL BARS)

VALVE, SINGLE FLOW PATH, NORMALLY CLOSED Schematics

2

22484 (21707) (12/04)

METHODS OF OPERATION

METHODS OF OPERATION

PRESSURE COMPENSATOR

LEVER

DETENT

PILOT PRESSURE

MANUAL

SOLENOID

MECHANICAL

SOLENOID CONTROLLED, PILOT PRESSURE OPERATED

PEDAL OR TREADLE

SPRING

PUSH BUTTON

SERVO

Schematics

3

22484 (21707) (12/04)

Schematics

4

22484 (21707) (12/04)

(N.O.) (N.C.) (H.O.) (H.C.) (T.O.) (T.C.)

NOTE:

2 POLE

NORMALLY OPEN NORMALLY CLOSED HELD OPEN HELD CLOSED TIMED OPEN TIMED CLOSED

COIL • (NUMBER)

CONNECTOR MATING

CIRCUIT BREAKERS

SINGLE POLE

CAPACITOR

BATTERY • ALWAYS POSITIVE

ARMATURE W/BRUSHES

AC VOLTAGE SOURCE

AC MOTOR

3 POLE

AC

GROUND

FUSE

BRIDGE DIODES

DC

LIGHT • (COLOR)

JUMPER

INDUCTIVE FIELD

HORN

HEATING ELEMENT

SIMPLE

DC

AC

N.C. N.O. CONTACTS

S.C.R.

FREQ

N.O. N.O. PUSHBUTTONS

OVERLOAD HEATER

OUTLET (HOUSE TYPE)

VOLT METERS

DPST SWITCHES

SOLENOID COIL

SHIELDED CABLE

SPDT

GENERAL VARIABLE RESISTORS

AMP

N.C. H.O. DIRECT ACTUATED

H.C.

TIMER CONTACTS

T.C. T.O. ENERGIZED

T.O. T.C. DE-ENERGIZED

GENERAL IRON CORE TRANSFORMER

PNP NPN TRANSISTORS

UNSHIELDED SHIELDED THERMOCOUPLE

SWITCHES

N.O. N.O. VACUUM & PRESSURE ACTUATED

N.C. N.O. TEMPERATURE ACTUATED

N.O. LIMIT SW

N.C. N.O. FLOW ACTUATED

A Terex Company

4418-547

10/94 Page 1 of 2 CR551 Pavers Electrical Schematic 9704-415-20b 9704-415-22a 9704-415-29a Cedarapids Inc.

A Terex Company

4418-547

10/94 Page 2 of 2

A Terex Company

4418-585

10/94

Page 1 of 2 CR561 Paver Electrical Schematic 9704-415-21b 9704-415-24a 9704-415-29a Cedarapids Inc.

A Terex Company

4418-585

10/94 Page 2 of 2

A Terex Company

4418-631

10/94

Page 1 of 2 CR451 Paver Electrical Schematic 9704-415-33c 9704-415-37b 9704-415-40b Cedarapids Inc.

A Terex Company

4418-631

10/94 Page 2 of 2

A Terex Company

4418-632

10/94

Page 1 of 2 CR461 Paver Electrical Schematic 9704-415-34c 9704-415-38b 9704-415-40b Cedarapids Inc.

A Terex Company

4418-632

10/94 Page 2 of 2

A Terex Company

4418-638

8/88

Page 1 of 1 Stretch 20 Screed Hydraulic Schematic 9704-657-41a Cedarapids Inc.

A Terex Company

4418-639

12/99

10' Fastach Std. Screed Hydraulic Schematic 4418-639a Cedarapids Inc.

A Terex Company

4418-642

2/90

Page 1 of 2 CR461 Paver (Track) Hydraulic Schematic 9704-657-05e Cedarapids Inc.

A Terex Company

4418-642

2/90 Page 2 of 2

A Terex Company

4418-643

2/90

Page 1 of 2 CR451 Paver (Rubber Tire) Hydraulic Schematic 9704-657-06f Cedarapids Inc.

A Terex Company

4418-643

2/90 Page 2 of 2

A Terex Company

4418-663

4/89

Page 1 of 2 CR451 Pavers Electrical Schematic 9704-415-58c 9704-415-37b 9704-415-59b Cedarapids Inc.

A Terex Company

4418-663

4/89 Page 2 of 2

A Terex Company

4418-664

4/89

Page 1 of 2 CR461 Electrical Schematic 9704-415-60a 9704-415-38b 9704-415-58c Cedarapids Inc.

A Terex Company

4418-664

4/89 Page 2 of 2

A Terex Company

4418-671

2/90

Page 1 of 2 CR351 Hydraulic Schematic 9704-658-32c Cedarapids Inc.

A Terex Company

4418-671

2/90 Page 2 of 2

A Terex Company

4418-672

2/90

Page 1 of 2 CR361 Pavers Hydraulic Schematic 9704-658-33c Cedarapids Inc.

A Terex Company

4418-672

2/90 Page 2 of 2

A Terex Company

4418-682

2/90

Page 1 of 2 CR351 Paver (Rubber Tire) Electrical Schematic 9704-415-67c 9704-415-71 9704-415-75d Cedarapids Inc.

A Terex Company

4418-682

2/90 Page 2 of 2

A Terex Company

4418-683

2/90

CR361 Paver (Track) Electrical 9704-415-68c 9704-415-72 9704-415-75d Cedarapids Inc.

A Terex Company

4418-683

2/90 Page 2 of 2

A Terex Company

4418-687

5/89

Page 1 of 2 CR551 Hydraulic Schematic 9704-658-48a Cedarapids Inc.

A Terex Company

4418-687

5/89 Page 2 of 2

A Terex Company

4418-688

2/90

Page 1 of 2 CR551 Paver (Track) Hydraulic Schematic 9704-658-49a Cedarapids Inc.

A Terex Company

4418-688

2/90 Page 2 of 2

A Terex Company

4418-698

6/90

10' Fastach Screed Hydraulic Schematic 9704-658-80a Cedarapids Inc.

A Terex Company

4418-703

3/90

8' Standard Screed Hydraulic Schematic 9704-658-85 Cedarapids Inc.

A Terex Company

4418-724 Sheet 1 of 4

8/94

CR461 & CR561 Pavers Electrical Schematic 9704-416-02f 9704-416-06c 9704-416-08c Cedarapids Inc.

A Terex Company

4418-724 Sheet 2 of 4

8/94

CR461 & CR561 Pavers Electrical Schematic 9704-416-02f 9704-416-06c 9704-416-08c Cedarapids Inc.

A Terex Company

4418-724 Sheet 3 of 4

8/94

CR461 & CR561 Pavers Electrical Schematic 9704-416-02f 9704-416-06c 9704-416-08c Cedarapids Inc.

A Terex Company

4418-724 Sheet 4 of 4

8/94

CR461 & CR561 Pavers Electrical Schematic 9704-416-02f 9704-416-06c 9704-416-08c Cedarapids Inc.

A Terex Company

4418-725 Sheet 1 of 4

8/94

CR451 and CR551 Pavers Electrical Schematic 9704-416-01f 9704-416-05d 9704-416-08c Cedarapids Inc.

A Terex Company

4418-725 Sheet 2 of 4

8/94

CR451 and CR551 Pavers Electrical Schematic 9704-416-01f 9704-416-05d 9704-416-08c Cedarapids Inc.

A Terex Company

4418-725 Sheet 3 of 4

8/94

CR451 and CR551 Pavers Electrical Schematic 9704-416-01f 9704-416-05d 9704-416-08c Cedarapids Inc.

A Terex Company

4418-725 Sheet 4 of 4

8/94

CR451 and CR551 Pavers Electrical Schematic 9704-416-01f 9704-416-05d 9704-416-08c Cedarapids Inc.

A Terex Company

4418-727

3/91

Page 1 of 2 CR451 and CR551 Pavers Hydraulic Schematic 9704-659-14b Cedarapids Inc.

A Terex Company

4418-727

3/91 Page 2 of 2

A Terex Company

4418-728

3/91

Page 1 of 2 CR461 and CR561 Pavers Hydraulic Schematic 9704-659-15 Cedarapids Inc.

A Terex Company

4418-728

3/91 Page 2 of 2

A Terex Company

4418-748

11/91

10-Foot Screed with EZ Screed II Hydraulic Schematic Cedarapids Inc.

Operation & Maintenance Manual

4418-771 451 Paver with Steer Assist Electrical Schematic 9704-416-11a Cedarapids Inc.

11/04

A Terex Company

4418-772

3/92

MS-1, MS-2, & MS-3 Mat Smoothness Machines Electric Schematic Cedarapids Inc.

A Terex Company

4418-773

6/92

Page 1 of 1 8' Screed w/EZ Screed II Hydraulic Schematic 04418-773 Cedarapids Inc.

A Terex Company

4418-793

5/93 Page 1 of 2 CR411 Pavers Hydraulic Schematic 9704-660-38a Cedarapids Inc.

A Terex Company

4418-793

5/93 Page 2 of 2

A Terex Company

4418-798 Sheet 1 of 4

8/94

CR361 w/Analog Display Electrical Schematic 9704-416-14d 9704-416-16a 9704-416-20 Cedarapids Inc.

A Terex Company

4418-798 Sheet 2 of 4

8/94

CR361 w/Analog Display Electrical Schematic 9704-416-14d 9704-416-16a 9704-416-20 Cedarapids Inc.

A Terex Company

4418-798 Sheet 3 of 4

8/94

CR361 w/Analog Display Electrical Schematic 9704-416-14d 9704-416-16a 9704-416-20 Cedarapids Inc.

A Terex Company

4418-798 Sheet 4 of 4

8/94

CR361 w/Analog Display Electrical Schematic 9704-416-14d 9704-416-16a 9704-416-20 Cedarapids Inc.

A Terex Company

4418-799 Sheet 1 of 4

8/94

CR351 and CR411 Pavers Electrical Schematic 9704-416-13e 9704-416-15b 9704-416-20 Cedarapids Inc.

A Terex Company

4418-799 Sheet 2 of 4

8/94

CR351 and CR411 Pavers Electrical Schematic 9704-416-13e 9704-416-15b 9704-416-20 Cedarapids Inc.

A Terex Company

4418-799 Sheet 3 of 4

8/94

CR351 and CR411 Pavers Electrical Schematic 9704-416-13e 9704-416-15b 9704-416-20 Cedarapids Inc.

A Terex Company

4418-799 Sheet 4 of 4

8/94

CR351 and CR411 Pavers Electrical Schematic 9704-416-13e 9704-416-15b 9704-416-20 Cedarapids Inc.

Operation & Maintenance Manual

A Terex Company

B TO STRAINER PAGE 2

200 MESH STRAINER

5000 PSI

49 CID

CID

3.35

.86 CID

2500 RPM

36.3 GPM MAX

9.3 GPM

5µ ß2 25 PSI BY-PASS

5000 PSI 350 PSI

LH TRACTION PUMP COOLER

PARKING B RAKE

FRONT WHEEL ASSIST (OPTIONAL)

TRACTION DRIVE .078" DIA. ORIFICES

TO AUXILIARY FILTER PAGE 2

TRACTION DRIVE

D

RANGE SHIFT

C

TO RH CONVEYOR CHARGE PUMP PAGE 2

RH TRACTION PUMP 350 PSI

COOLER

5000 PSI 2500 RPM 3.35 CID

9.3 GPM

.86 CID

5¨ ß2 25 PSI BY-PASS 49 CID

5000 PSI

A TO STRAINER PAGE 2

4418-808

4/94

200 MESH STRAINER

CR451-CR551 Hydraulic Schematic w/Servo 9704-660-53 Pages 1 & 2 Cedarapids Inc.

Operation & Maintenance Manual

A Terex Company

TRUCK HOOK (OPTIONAL)

LH PULL POINT

RH PULL POINT

HOPPER WINGS

175 PSI NITROGEN PRECHARGE

SCREED ASSIST (SUPPLED WITH STRETCH 20)

OPTIONAL REAR WHEEL SUSPENSION

SCREED LIFT SCREED LIFT

E

STEERING

REPHASE PORT AT EACH END OF CYLINDER STROKE

V A D

STEERING VALVE

900 PSI I

SCREED EXTENSIONS (OPTIONAL)

T

P

FLOW TO SCREED VALVES FLOW FROM SCREED VALVES

T

FULL

TO FRONT WHEEL DRIVE PAGE 1

IDLE

SCREED VIBRATORS

D

THROTTLE

FLOW FROM SCREED VIBRATORS

5µ ß2 RH CONVEYOR C

LH CONVEYOR

REPHASE PORT CROSS SECTION

5µ ß2

9.9 GPM MAX

5µ ß2

1500 PSI

TO PARKING BRAKE AND RANGE SHIFT PAGE 1

FLOW TO SCREED VIBRATORS

HOOD RAISING SYSTEM

.85 CID

.913 CID

AUXILIARY PUMP

2.8 CID

2500 RPM

2500 PSI

2.8 CID

220 PSI

2.8 CID

3800 PSI

2.8 CID

2500 RPM

2500 RPM MAX

9.2 GPM

30.3 GPM MAX

2500 RPM MAX

3800 PSI

.85 CID

2500 RPM

220 PSI

1.2 CID

9.2 GPM

13 GPM

30.3 GPM MAX

900 PSI (2.1 GPM MAX) 12 VDC

TO TRACTION PUMP PAGE 1 B

A

200 MESH STRAINERS

TO TRACTION PUMP PAGE 1 12 VDC

4418-808

Page 2

Operation & Maintenance Manual

A Terex Company

B TO STRAINER PAGE 2

200 MESH STRAINER

5000 PSI

TRACK TENSIONING

2500 RPM

36.3 GPM MAX

5µ ß2 25 PSI BY-PASS

0.86 CID

3.35 CID

2050 PSI

9.3 GPM

5000 PSI 350 PSI

LH TRACTION PUMP

COOLER

PARKING BRAKE TRACTION DRIVE

TRACTION DRIVE RANGE SHIFT

C

TRACK TENSIONING

TO RH CONVEYOR CHARGE PUMP PAGE 2

RH TRACTION PUMP

2050 PSI

350 PSI

COOLER

36.3 GPM MAX

5000 PSI 2500 RPM

3.35 CID

5µ ß2 25 PSI BY-PASS

.86 CID

5000 PSI

A TO STRAINER PAGE 2

200 MESH STRAINER

4418-809

4/94

CR461 and CR561 Pavers Hydraulic Schematic 9704-660-54 Pages 1 & 2 Cedarapids Inc.

Operation & Maintenance Manual

A Terex Company

LH PULL POINT

TRUCK HOOK (OPTIONAL)

RH PULL POINT

SCREED ASSIST (SUPPLED WITH STRETCH 20)

HOPPER WINGS

HOOD RAISING SYSTEM

E SCREED LIFT 175 PSI NITROGEN PRECHARGE V A

D

900 PSI

SCREED EXTENSIONS (OPTIONAL)

900 PSI T

I 12.1 GPM MAX

P

FLOW TO SCREED VALVES FLOW FROM SCREED VALVES

12 VDC

T

SCREED VIBRATORS IDLE

FULL

THROTTLE

FLOW FROM SCREED VIBRATORS

LH CONVEYOR

5µ ß2

2.8 CID

TO TRACTION PUMP PAGE 1

9.2 GPM 2.8 CID

.85 CID

2500 RPM

.913 CID

AUXILIARY PUMP

2.8 CID

220 PSI

2.8 CID

2500 RPM MAX.

3800 PSI

2500 RPM MAX.

3800 PSI

1.2 CID

30.3 GPM MAX

2500 RPM

220 PSI

1.2 CID

30.3 GPM MAX

9.2 GPM

13 GPM

FLOW TO SCREED VIBRATORS

2500 PSI

RH CONVEYOR

12 VDC

19.9 GPM MAX

5µ ß2

1500 PSI

6µ ß8

TO PARKING BRAKE AND RANGE SHIFT PAGE 1 C

TO TRACTION PUMP PAGE 1 B

A 200 MESH STRAINERS

4418-809

4/94

CR461 and CR561 Pavers Hydraulic Schematic 9704-660-54 Pages 1 & 2 Cedarapids Inc.

Operation & Maintenance Manual

A Terex Company

4418-810 Stretch 18 Hydraulic Schematic 9704-660-56 Cedarapids Inc.

4/94

4

4

30A.

POWER

15A.

LIGHTS

K1

15A.

ENGINE

60A.

15A.

CONTROL

4

BURNER

15A.

FLASHERS

4

4

1

1

1

1

1

46

20

113

109

4418-815

46

46

46

46

46

46

46

46

46

115

115

115

115

115

115

115

115

115

109

21

HIGH

OFF

110

148

146

138

136

128

126

118

116

VM

FUEL

OT

OP

WT

K1

114

W

105

101

REL

110

112

HI/LO BEAM HEAD LGTS.

111

105

YEL

101

YEL

14

LT.

TD

RED

106

RED

102

128

126

138

136

148

146

RT. EXT. BURNER (NO.4)

GLOW PLUG NO.4

TRAVEL

PAVE

DECREASE

42

190

189

186

42

48

B SOL.

A SOL.

B SOL.

RANGE SOL.

THROTTLE SOL.

CR461 and CR561 Electrical Schematic 9704-416-32 9704-416-06c 9704-416-08 Cedarapids Inc.

3

3

3

3

3

3

3

A SOL. 185 UP

DOWN

3

B SOL. 176 DOWN

3

3

A SOL.

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

175

W R

W

UP

A SOL.

B SOL.

A SOL.

B SOL.

A SOL.

B SOL.

A SOL.

GLOW PLUG NO.4

FAN MOTOR NO.4

GLOW PLUG NO.3

FAN MOTOR NO.3

GLOW PLUG NO.2

FAN MOTOR NO.2

GLOW PLUG NO.1

FAN MOTOR NO.1

FUEL PUMP MOTOR

110

WORK LGTS.

HI BEAM HEAD LGTS.

111

3

3

3

3

3

3

3

A

HORN

R.H. GATE MOTOR

HORN SW.

19

K18

K16

L.H. GATE MOTOR

K2

3

3

3

~)

B SOL.

183

174

173

182

181

172

171

W R

W

106

102

15

STARTER RELAY

FUEL SOL.

TEMP. (223

3

3

3

3

3

3

184

INCREASE

FULL

118

116

LT. EXT. BURNER (NO.3)

GLOW PLUG NO.3

RT.

23

5

5

OIL PRESS (5#)

SENSOR

SENSOR

SENSOR

3

3

3

3

3

3

OUT

IN

OUT

IN

DECREASE

INCREASE

DECREASE

2

117

RT. MAIN BURNER (NO.2)

GLOW PLUG NO.2

16

(NC)

10

9

8

SENSOR

STARTER MOTOR

OVERHEAD STROBE

W

18

K17

K18

K15

K16

LT. MAIN BURNER (NO.1)

GLOW PLUG NO.1

(S)

(NO)

G

G

S

G

S

G

S

7

CLOSED IN NEUTRAL (TRAVEL CONTROLS)

CR

OPTIONAL SCREED CONTROLS INCREASE

S

G

G

FASTACH SCREED BURNER CONTROL

112

IDLE

RANGE

ON

OFF

ON

OFF

ON

OFF

ON

117

LOW

110

OFF

CROWN

MAIN

HEIGHT

RH MATCH

MATCH HEIGHT

LH

RH EXTEND

EXTEND

LH

RH SLOPE

SLOPE

LH

FAN NO.4

FAN NO.3

FAN NO.2

FAN NO.1

10A.

FUEL PUMP

d

K17

K15

'A'

ENG

FU-1 SFE-14

(B)

MURPHY RELAY #758-A-NG

18 K3 HORN RELAY

S

H/T

POWER RELAY

I

I

I

I

I

I

11

3

STARTER SOL.

1

ENGINE SAFETY SHUTDOWN

22

VOLTMETER

FUEL LEVEL

OIL TEMP.

W

GND

2

OIL PRESS.

WATER TEMP.

100

OFF

ON

D+

B+

19

K3

K2

HOUR/TACHOMETER

1

1

ALTERNATOR

BRAKE 13

22

22

22

22

22

22

22

22

12 V.D.C.

100

100

100

100

100

START

RUN

STOP

START

RUN

STOP

6

PRESS. SW.

ENGINE

0

THROTTLE

d

21

22

22

LIGHTS

MAIN KEYSWITCH

MAIN KEYSWITCH

46

46

46

46

46

46

46

46

46

46

46

46

46

46

46

46

46

ENGAGE

47

47

J

I

H

G

F

E

D

C

B

A

J

I

H

G

F

E

D

C

B

A

RH GATE

GATE

LH

WINGS

HOPPER

SCREED LIFT

165A

167A

167A

165A

46

3

160

162

MAN

SET

AUTO

51

78

3

77

34

(12)

(6)

(5)

(1)

(2)

(3)

(7)

ADJUST. SPEED MODULE

80

(D)

FEED SENSOR

46

54

56

53

(7)

ADJUST. SPEED MODULE

90

(D)

FEED SENSOR

(12)

(6)

(5)

(1)

(2)

(3)

(E)

(E)

(9)

(8)

(4)

(11)

(10)

(8)

(9)

(C)

(4)

(11)

(10)

R.H. FEED CONTROL

46

52

55

(C)

8

1

3

150

7

LAI

6

3

2

157

155

155

157

DEC

INC

157

155

LT. AUTO ISOLATION RELAY

157

155

RAI

6

3

2

167

165

INC

165

167

DEC

165

167

ENGAGE

LOWER

RAISE

LOWER

RAISE

LOWER

RAISE

LOWER

RAISE

RELEASE

4

ASSIST 64

33

108

107

104

103

66

65

ON

OFF

64

63

62

61

10 PIN RECEPTACLE FOR AUTO CABLE

8

1

3

160

7

RT. AUTO ISOLATION RELAY

'D'

'A' SOL.

'B' SOL.

'A' SOL.

'B' SOL.

AREA

68 Q 2W.

B

A

B

A

'A' SOL.

'B' SOL.

RH

RH

A

97

K18

K17

K16

K15

A

C

B

C

B

B

POINT

5

REVISION

RT. PULL POINT SERVO

SERVO

1K Q

SPEED

MAN. CONV.

B

MAN. CONV. SPEED 1K Q

LT. PULL

SERVO

R.H. FEED

CW

STOP

A

C

B

3

D

A

L.H. FEED SERVO 87

STOP

A

C

B CW

VIBRATOR SOL.

3

COIL

REVERSE COIL

VIBRATOR SOL.

'C'

68 Q 2W.

93

3

96

95

94

83

3

86

85

84

50

50

LH

FORWARD COIL

SPEED 1K Q

MAX PAVER

78

3

77

D

LH

COIL

A

REVERSE

SPEED 1K Q

MAX PAVER

ASSIST SOL.(OPT)

SYM.

167

165

R.H. AUTOMATIC SCREED CONTROL

162

CW

74

3

3 74

73

FORWARD

BRAKE RELEASE SOL.

73

34

10 PIN RECEPTACLE FOR AUTO CABLE

152

MAT THICKNESS

157A

155A

157A

155A

46

3

150

152

MAN

SET

AUTO

53

51

ON

AUTO

A

C

B

B

D

A

C

A

C

B

B

D

A

C

L.H. FEED CONTROL

OFF

47

VIBRATORS

ON

OFF

VIBRATORS

34

34

L.H. AUTOMATIC SCREED CONTROL

STOP

56

47

47

47

MAT THICKNESS

'D'

OVERRIDE

REMOTE FEED

MAN

OFF

AUTO

4

55

STOP

R.H. CONVEYOR

'C'

OVERRIDE

REMOTE FEED

MAN

OFF

SPEED

TRAVEL

CONTROLLER

AUTO

L.H. CONVEYOR

RT. FORWARD L.S.

LT. FORWARD L.S.

(TRAVEL CONTROL)

34

CONTROLLER

SPEED

TRAVEL

RELEASE

CLOSED IN FORWARD

NOTE:

OPTIONAL TRUCK HITCH

47

47

34

34

34

34

'A'

BRAKE

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

VIBRATOR WIRING

OPTIONAL EZ SCREED

STANDARD SCREED VIBRATOR WIRING

Operation & Maintenance Manual

11/04

Operation & Maintenance Manual

23

C

5

S

3

B

NC

NO

22

758A-NG TIMING

4

1

RELAY

C 22

3

3

3

3

3

3

5

5

7

7

8

8

9 10

9 10

11

VIEW C-C

11

15

15

18

18

19

19

RELAY WIRING 20 21

A

27

33

33

34

34

46

MODULE OPTIONAL

20

22 23

27

46 LEFT

15

ENGINE

1

3 46

109

80 85 84 86

52 55 51 83

25

LIGHTS

4

c

47

48

48

50

50

RIGHT

15

FLASHERS

4

OPTIONAL

113

T1

52

53

53

54

54

55

55

56

56 61

62

62

63

63

64

64

65

65

66

66

70

70

71

71

73

73

74

74

77

77

78

78

3

46

3

3

90 95 94 96 3 46

54 56 53 93

15

CONTROL

4

51

52

61

R.H. PROPORTIONAL MODULE

42 46 46

47

51 T1

21

22 23

42

L.H. PROPORTIONAL

20

3

3

3

3

30

POWER

4

3

80

80

83

83

84

84

85

85

86

86

87

87

90

90

93

93

94

94

100

60

BURNER

4

95

95

96

96

97

115

B

100

100

100

100

100

100

100

101

A SPARE

101

102

102

103

103

104

104

105 106

105 106

107

107

108

108

109

109

110

K3

97

100

111

110 111

112

112

113

113

114

114

117

117

K15

VIEW A-A

155

155

157

157

165

165

167

167

115

115

C.B. WIRING

K16

K17

3

3

3

3

K18

B

100

3

3

3 108

3

107 106

K18

104

19 3

3

105

K17

100

100

100 3

103

102

K16

K15

3

100

101

100

18

K3

SPARE

VIEW B-B

4418-815

11/04

4

4

30A.

POWER

15A.

LIGHTS

K1

15A.

ENGINE

60A.

15A.

CONTROL

4

BURNER

15A.

FLASHERS

4

4

1

1

1

1

1

46

20

113

109

4418-816

46

46

46

46

46

46

46

115

115

115

115

115

115

115

115

115

109

c

21

22

22

0

21

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

148

146

138

136

128

126

118

116

117

LOW

110

110

OFF

CROWN

MAIN

HEIGHT

RH MATCH

HEIGHT

LH MATCH

RH EXTEND

LH EXTEND

RH SLOPE

SLOPE

LH

FAN NO.4

FAN NO.3

FAN NO.2

FAN NO.1

10A

FUEL PUMP

HIGH

OFF

K3

c

K1

UP

OUT

IN

OUT

IN

W

110

112

HI/LO BEAM HEAD LGTS.

111

105

YEL

101

YEL

14

RED

106

RED

102

117

118

116

138

GLOW PLUG NO.4 148

146

RT. EXT. BURNER (NO.4)

GLOW PLUG NO.3

136

LT. EXT. BURNER (NO.3)

128

126

RT. MAIN BURNER (NO.2)

GLOW PLUG NO.2

K18

K16

DECREASE

190

B SOL.

CR551 Pavers w/Servo Electrical Schematic 9704-416-31 9704-416-05d 9704-416-08c Cedarapids Inc.

3

3

3

A SOL.

3

3

3

3

3

3

3

3

189

3

3

3

3

3

3

3

3

3

3

3

3

3

3

INCREASE

W R

3

3

A SOL.

B SOL.

A SOL.

B SOL.

A SOL.

B SOL.

A SOL.

B SOL.

A SOL.

B SOL.

A SOL.

GLOW PLUG NO.4

FAN MOTOR NO.4

GLOW PLUG NO.3

FAN MOTOR NO.3

GLOW PLUG NO.2

FAN MOTOR NO.2

GLOW PLUG NO.1

FAN MOTOR NO.1

FUEL PUMP MOTOR

110

WORK LGTS.

LGTS.

W

3

3

3

3

3

3

3

3

3

~)

3

3

3

3

3

3

B SOL.

A

HORN

R.H. GATE MOTOR

HI BEAM HEAD

111

K2

L.H. GATE MOTOR

HORN SW.

19

FUEL SOL.

TEMP. (223

STARTER RELAY

5

5

OIL PRESS (5#)

SENSOR

SENSOR

SENSOR

3

3

3

3

3

186

185

176

175

184

183

174

173

182

181

172

171

W R

W

106

102

15

23

OVERHEAD STROBE

W

18

K17

K18

K15

K16

LT. MAIN BURNER (NO.1)

GLOW PLUG NO.1

(NC)

10

9

CLOSED IN NEUTRAL (TRAVEL CONTROL)

L.S.3

(S)

(NO)

G

G

S

G

S

8

7

SENSOR

STARTER MOTOR

3

DOWN

UP

DOWN

2

DECREASE

INCREASE

DECREASE

S G

TD

OPTIONAL SCREED CONTROLS INCREASE

S

G

G

FASTACH SCREED BURNER CONTROL

112

105

101

REL

114

18

K17

K15

'A'

ENG

FU-1 SFE-14

CR

MURPHY RELAY #758-A-NG

(B)

100

HORN RELAY

VM

FUEL

OT

OP

WT

H/T

S

POWER RELAY

I

I

I

I

I

I

11

3

STARTER SOL.

1

ENGINE SAFETY SHUTDOWN

22

VOLTMETER

FUEL LEVEL

OIL TEMP.

W

GND

2

OIL PRESS.

19

K3

D+

B+

WATER TEMP.

BRAKE 13

22

22

22

22

22

22

22

22

1

K2

ALTERNATOR

1

HOUR/TACHOMETER

12 V.D.C.

100

100

100

100

100

START

RUN

STOP

START

RUN

STOP

6

PRESS. SW.

ENGINE

LIGHTS

MAIN KEYSWITCH

MAIN KEYSWITCH

46

46

46

46

46

46

46

46

46

46

46

46

46

46

46

46

46

46

46

46

ENGAGE

J

I

H

G

F

E

D

C

B

A

J

I

H

G

F

E

D

C

B

A

THROTTLE

GATE

RH

GATE

LH

REAR FRAME

WINGS

HOPPER

SCREED LIFT

165A

167A

167A

165A

46

3

160

162

MAN

SET

AUTO

CW

ON

51

(12)

(6)

(5)

(1)

(2)

(3)

(7)

ADJUST. SPEED MODULE

80

(D)

FEED SENSOR

53

46

54

56

(7)

ADJUST. SPEED MODULE

90

(D)

FEED SENSOR

(12)

(6)

(5)

(1)

(2)

(3)

(E)

(E)

(9)

(8)

(4)

(11)

(10)

(8)

(9)

(C)

(4)

(11)

(10)

R.H. FEED CONTROL

46

52

55

(C)

8

1

3

150

7

LAI

6

3

2

157

155

155

157

DEC

INC

157

155

LT. AUTO ISOLATION RELAY

157

155

RAI

6

3

2

167

165

165

167

DEC

INC

167

165

LOWER

RAISE

LOWER

RAISE

LOWER

RAISE

LOWER

RAISE

LOWER

FULL

IDLE

4

RAISE

RELEASE

ENGAGE

64

ASSIST 33

64

108

107

104

103

71

70

66

65

ON

OFF

63

62

61

10 PIN RECEPTACLE FOR AUTO CABLE

8

1

3

160

7

RT. AUTO ISOLATION RELAY

48

'D'

AREA 'A' SOL.

'B' SOL.

'A' SOL.

'B' SOL.

68 Q 2W.

87

A

B

A

B

B SOL.

A SOL.

'A' SOL.

'B' SOL.

LH

LH

D

A

97 B

MAN. CONV. SPEED 1K Q

B

SPEED 1K Q

5

REVISION

RT. PULL POINT SERVO

POINT SERVO

LT. PULL

THROTTLE SOL.

K18

K17

K16

K15

A

C

C

B

B

MAN. CONV.

5

RH

R.H. FEED SERVO

CW

STOP

A

C

B

3

D

A

L.H. FEED SERVO

CW

STOP

A

C

B

3

RH

FORWARD COILS

VIBRATOR SOL.

'C'

68 Q 2W.

93

3

96

95

94

83

3

86

85

84

50

78

A REVERSE COILS

VIBRATOR SOL.

ASSIST SOL.(OPT)

SYM.

167

165

R.H. AUTOMATIC SCREED CONTROL

162

50

MAX PAVER SPEED 1K Q

74

3

74

73

3

77

BRAKE RELEASE SOL.

RANGE SOL.

FWD SOL.

73

AUTO VIBRATORS

A

C

B

A

D

10 PIN RECEPTACLE FOR AUTO CABLE

152

MAT THICKNESS

157A

155A

157A

155A

46

3

150

152

MAN

SET

AUTO

53

51

C B

34

L.H. FEED CONTROL

OFF

47

ON

OFF

VIBRATORS

34

34

42

27

L.H. AUTOMATIC SCREED CONTROL

STOP

56

46

47

47

MAT THICKNESS

'D'

OVERRIDE

REMOTE FEED

MAN

OFF

AUTO

CONVEYOR

R.H.

'C'

55

STOP

OVERRIDE

FEED

REMOTE

MAN

OFF

SPEED

TRAVEL

34

42

27

CONTROLLER

34

RELEASE

AUTO

L.H. CONVEYOR

FORWARD L.S.

OPTIONAL TRUCK HITCH

47

47

47

47

34

P/2

P/4

TRAVEL

NOTE: CLOSED IN FORWARD (TRAVEL CONTROL)

'A'

BRAKE

RANGE

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

OPTIONAL EZ SCREED VIBRATOR WIRING

STANDARD SCREED VIBRATOR WIRING

Operation & Maintenance Manual

11/04

Operation & Maintenance Manual

VIEW C-C RELAY WIRING

VIEW A-A CB WIRING

4418-816

11/04

CR551 Pavers w/Servo Electrical Schematic 9704-416-31 9704-416-05d 9704-416-08c Cedarapids Inc.

Operation & Maintenance Manual

A Terex Company

4418-818 Stretch 16 Screed Hydraulic Schematic 9704-660-55 Cedarapids Inc.

4/94

Operation & Maintenance Manual

A Terex Company

.063"

300-310 PSI

MACHINE RAISE 2.8 "B"

CID

"A"

CONVEYOR PUMP 400 PSI

52.8 GPM MAX 50:1 RATIO N.S. SWITCH 2400 PSI

2000 RPM 5µ 6.1 CID

50:1 RATIO

"A"

2.8

"B" FORWARD

3600 PSI

1.2 CID

ß2

10.1 GPM 1.2 CID 1940 RPM

1000 PSI

"A" REVERSE

10.4 GPM

AUX. PUMP

"B"

CID

4418-831 300-310 PSI

.063"

MS1 & MS2 Hydraulic Schematic 9702-050-42 Cedarapids Inc.

4/94

Operation & Maintenance Manual

A Terex Company

HOPPER GATE

MACHINE RAISE

PUSH BEAM

HOPPER RAISE

TRUCK HOOK (OPTIONAL)

.063" 300-310 PSI

200 PSI PRECHARGE 1 PINT EACH

2.8 "B"

CID

"A"

CONVEYOR PUMP 50:1 RATIO

400 PSI

52.8 GPM MAX

B

N.S. SWITCH

2000 RPM

CID

"B" FORWARD

B A

B A

A

2400 PSI

6.1

50:1 RATIO

B A

1.2 CID

1000 PSI

"A" REVERSE

B A

10.4 GPM

5µ ß2

10.1 GPM 1.2 CID

3600 PSI

AUX. PUMP

1940 RPM

"A"

2.8

"B"

CID

4418-832

300-310 PSI .063"

MS3 Hydraulic Schematic 9702-050-43 Cedarapids Inc.

4/94

A Terex Company

4418-861

12/94

Page 1 of 2 CR461 and CR561 Pavers with Frame Raise Hydraulic Schematic 9704-660-90

A Terex Company

4418-861

12/94 Page 2 of 2

A Terex Company

4418-864

2/95

Page 1 of 4 Grayhound Track Pavers Electrical Schematic 9704-416-54b, 9704-416-56c, 9704-416-57a, 9704-416-59a

Cedarapids Inc.

A Terex Company

4418-864

2/95 Page 2 of 4

A Terex Company

4418-864

2/95 Page 3 of 4

A Terex Company

300 Only

400 & 500 Only

300 Only

4418-864

2/95 Page 4 of 4

A Terex Company

4418-865

2/95

Page 1 of 4 Rubber Tire Pavers Electrical Schematic 9704-416-53b, 9704-416-55b, 9704-416-57a, 9704-416-59a

Cedarapids Inc.

A Terex Company

4418-865

2/95 Page 2 of 4

A Terex Company

4418-865

2/95 Page 3 of 4

A Terex Company

300 & 411 Only

400 & 500 Only

300 & 411 Only

4418-865

2/95 Page 4 of 4

A Terex Company

4418-867

3/95 Page 1 of 1

Fastach 8 Screed with Vibratory Strike-off Hydraulic Schematic Cedarapids Inc.

A Terex Company

4418-923

12/96

Page 1 of 4 Grayhound Pavers Electrical Schematic 9704-416-80 9704-416-81 9704-416-57a 9704-416-59a Cedarapids Inc.

A Terex Company

4418-923

12/96 Page 2 of 4

A Terex Company

300 & 411 Only

400 & 500 Only

300 & 411 Only

4418-923

12/96 Page 3 of 4

A Terex Company

4418-923

12/96 Page 4 of 4

A Terex Company

4418-937

12/97

Page 1 of 4 Rubber Tire Pavers Electrical Schematic ROC/Elite 9704-416-88 9704-416-55b 9704-416-86a

A Terex Company

4418-937

12/97 Page 2 of 4

A Terex Company

4418-937

12/97 Page 3 of 4

A Terex Company

4418-937

12/97 Page 4 of 4

A Terex Company

4418-938

12/97

Page 1 of 4 Track Pavers Electrical Schematic ROC/Elite 9704-416-89 9704-416-92 9704-416-86a

A Terex Company

4418-938

12/97 Page 2 of 4

A Terex Company

4418-938

12/97 Page 3 of 4

A Terex Company

4418-938

12/97 Page 4 of 4

4418-944

11/04

Page 1 of 2 CR351 Pavers Hydraulic Schematic 9704-661-58c Cedarapids Inc.

4418-944

11/04 Page 2 of 2

4418-945

11/04

Page 1 of 2 CR361 Pavers Hydraulic Schematic 9704-661-59c Cedarapids Inc.

4418-945

11/04 Page 2 of 2

A Terex Company

4418-946

10/98

Page 1 of 2 CR451/CR551 Slat Conveyor Pavers Hydraulic Schematic 9704-661-38b Cedarapids Inc.

A Terex Company

4418-946

10/98 Page 2 of 2

A Terex Company

4418-947

10/98

Page 1 of 2 CR461/CR561 Slat Conveyor Pavers Hydraulic Schematic 9704-661-39b Cedarapids Inc.

A Terex Company

4418-947

10/98 Page 2 of 2

A Terex Company

4418-952

10/98

Page 1 of 2 CR461 and CR561 Slat Pavers Rubber Track Hydraulic Schematic 9704-661-68

A Terex Company

4418-952

10/98 Page 2 of 2

4418-956

11/04

Page 1 of 2 CR361R Pavers Hydraulic Schematic 9704-661-78a Cedarapids Inc.

4418-956

11/04 Page 2 of 2

4418-959

11/04

Page 1 of 4 Rubber Tire Pavers Gen 3 Std. Electrical Schematic 9704-417-01c 9704-417-03d 9704-417-05a Cedarapids Inc.

4418-959

11/04 Page 2 of 4

4418-959

11/04 Page 3 of 4

4418-959

11/04 Page 4 of 4

4418-960

11/04 Page 1 of 4 Track Pavers Gen 3 Std. Electrical Schematic 9704-417-02d 9704-417-04d 9704-417-05a

4418-960

11/04 Page 2 of 4

4418-960

11/04 Page 3 of 4

4418-960

11/04 Page 4 of 4

4418-963

11/04 Page 1 of 4 Rubber Tire Pavers Remix Electrical Schematic 9704-417-06c 9704-417-07d 9704-417-09a

4418-963

11/04 Page 2 of 4

4418-963

11/04 Page 3 of 4

4418-963

11/04 Page 4 of 4

A Terex Company

4418-964

05/01 Page 1 of 4 Track Pavers Remix Electrical Schematic 9704-417-06c 9704-417-08c 9704-417-10c

A Terex Company

4418-964

05/01 Page 2 of 4

A Terex Company

4418-964

05/01 Page 3 of 4

A Terex Company

4418-964

05/01 Page 4 of 4

4418-973

11/04

Page 1 of 4 CR351 Pavers Gen 3 Electrical Schematic 9704-417-03d 9704-417-12c 9704-417-15c Cedarapids Inc.

4418-973

11/04 Page 2 of 4

4418-973

11/04 Page 3 of 4

4418-973

11/04 Page 4 of 4

4418-974

11/04

Page 1 of 4 CR361 Pavers Gen 3 Electrical Schematic 9704-417-04d 9704-417-12c 9704-417-14c Cedarapids Inc.

4418-974

11/04 Page 2 of 4

4418-974

11/04 Page 3 of 4

4418-974

11/04 Page 4 of 4

4418-978

11/04 Page 1 of 4 Rubber Tire Pavers Electrical Schematic Slat From Remix 9704-417-17 9704-417-16a 9704-417-18 Cedarapids Inc.

4418-978

11/04 Page 2 of 4

4418-978

11/04 Page 3 of 4

4418-978

11/04 Page 4 of 4

4418-994

11/04

Page 1 of 4 Track Pavers w/Dual Joysticks Gen 3 Std. Electrical Schematic 9704-417-22c 9704-417-23b 9704-417-05a

4418-994

11/04 Page 2 of 4

4418-994

11/04 Page 3 of 4

4418-994

11/04 Page 4 of 4

4418-995

11/04

Page 1 of 2 CR451/CR551 Slat Conveyor Pavers Hydraulic Schematic 9704-662-09a

4418-995

11/04 Page 2 of 2

4418-996

11/04

Page 1 of 2 CR461/CR561 Slat Conveyor Pavers Hydraulic Schematic 9704-662-10a

4418-996

11/04 Page 2 of 2

A Terex Company

4418-997

10/00

Page 1 of 2 CR461R/CR561R Rubber Track Slat Conveyor Pavers Hydraulic Schematic 9704-662-11

A Terex Company

4418-997

10/00 Page 2 of 2

4494-105-19b

Page 1 of 4

12/03

352 Paver Electrical Schematic 9704-417-33b, 9704-417-34b, 9704-417-35d

4494-105-19b

Page 2 of 4

12/03

352 Paver Electrical Schematic 9704-417-33b, 9704-417-34b, 9704-417-35d

4494-105-19b

Page 3 of 4

12/03

352 Paver Electrical Schematic 9704-417-33b, 9704-417-34b, 9704-417-35d

4494-105-19b

Page 4 of 4

12/03

352 Paver Electrical Schematic 9704-417-33b, 9704-417-34b, 9704-417-35d

4494-105-20

Page 1 of 4

11/04

362 Paver Electrical Schematic 9704-417-46b, 9704-417-47c, 9704-417-35d

4494-105-20

Page 2 of 4

11/04

362 Paver Electrical Schematic 9704-417-46b, 9704-417-47c, 9704-417-35d

4494-105-20

Page 3 of 4

11/04

362 Paver Electrical Schematic 9704-417-46b, 9704-417-47c, 9704-417-35d

4494-105-20

Page 4 of 4

11/04

362 Paver Electrical Schematic 9704-417-46b, 9704-417-47c, 9704-417-35d

NOTE:

SEE SHEET 2 OF 2 FOR ADDITIONAL CONTROLS

4494-105-21 Page 1 of 4 11/04

452/552 Paver Electrical Schematic 9704-417-36, 9704-417-55a, 9704-417-54a

4

4

4

4

1 K1

B50

15A.

46

A

MAINTENANCE

A

RUN START

WARNING

R

STOP

17

STOP

START

RUN

STOP

ENGINE 17

TWISTED

OPTION

J1939 TO ENGINE

45

ON

GENERATOR

OFF

FULL

THROTTLE

22

22

22

22

22

22

22

22

22

22

22

A

3

5A

S G

24

25

S

OT

OP

WT

G

S G

S G

S G

H/T

I

ON

125A FUSE

BATTERY + 1

125A FUSE

BATTERY + 1

BATTERY +

J1939 SH

J1939 -

1

2

POWER RELAY

K1

25

D

F

E

10R

10L

GRID

TWIN

-

6 AWG

6 AWG

E

D

C

A

B

G

F

DIAGNOSTIC

ENGINE BLOCK GROUND

UNIT

-

3

3

3

3

3

3

3

3

3

REMIX ONLY

3

46

46

46

46

46

46

46

47

15

14

25A.

LIGHTS

4 15A.

FLASHERS

4

RH GATE

LH GATE

REAR FRAME

HOPPER WINGS

47

SCREED LIFT

SCREED LIFT

RED

79

K6

K5

LOWER

RAISE

LOWER

RAISE

LOWER

RAISE

LOWER

RAISE

89C LOWER

RAISE

LOWER

RAISE

RELEASE

114

110

64

63

62

61

ON

W

114

HEAD LGTS.

110

108

107

104

103

71

70

66

65

ON

OFF

ALARM

64

74A

73A

34

3

CW

OFF

78

77

74

73

74A

73A

50

49

34

W

A

D

A

D

A

WORK LGTS.

110

K18

K17

K16

K15

78

77

74

73

STROBE

W

CRFA 89B 89A

ON

VIBRATORS 47

A

B

C

D

A

C

B

MAX PAVER SPEED 1K Q

OFF 33

ASSIST

47 F

ENGAGE

113A

47

49

WHT F

R

GRN

RED

BLK

RED

BLK

74A

73A

3

76

75

STEER ASSIST MODULE 46065-500-34

74A 73A

42

27

TRAVEL CONTROL HANDLE

79

WHT

34

76

75

R

L

ON

R

TRAVEL SPEED CONTROL MODULE

N

N

RELEASE

109A

WHT

RED

'A'

46A

46A

ENGAGE

BRAKE

OFF

STEER ASSIST

46A

DIFF. LOCK

P/4

P/2

TRAVEL

RANGE

OPTIONAL TRUCK HITCH

47

TO STARTING CIRCUIT

46

46

46

CONTINUED TO PAGE 2 OF SCHEMATIC

+

3

3

FLASHER RELAY 3 K6

HEATER

+

113

109

RH TANK

3

LIGHTS RELAY 3 K5

VOLTMETER

24

C

B

A

3

OIL TEMP. 9

3

3

3

3

LH TANK

2

3

OIL PRESS. 8

1

COOLING FAN

1 2 HYD DUMP

3

3

3

3

3

3

VENT VALVE

J1587 PUBLIC DATA LINK(-)

3

WATER TEMP. 7

W

Q

P

O

N

M

L

K

J

H

G

F

E

D

C

B

A

23 PIN

(LOCATED IN FUEL FILTER)

J1587 PUBLIC DATA LINK(+)

J1939 +

G

17

K2

3

3

3

STARTER RELAY

15

STARTER

HOUR/TACHOMETER

WIF SENSOR

ON

OFF

FLASHER

VM

10

OFF

LIGHTS

RH

I

I

I

I

11

FUEL LEVEL

10A

10A

7.5A

7.5A

7.5A

FUEL LH

L.S.3

1

CLOSED IN NEUTRAL (TRAVEL CONTROL)

5A

FUEL I

REL

14

2

GRID HTR RELAYS

21A

DECREMENT

INCREMENT

ON

OFF

DIAGNOSTIC

A

WATER IN FUEL

A

13

K2

ENG

BRAKE

100

12 V.D.C.

12 V.D.C.

WAIT TO START

HYD VENT 5A

21B

48

36

35

37

29

28

30

6

IDLE

E-STOP

0

5

21

CONSOLE

4

1

B49

B31

B41

B40

B47

1400 RPM

B36

B35

B37

B2

B11

B4

B3

B1

QSB

B28

FAULT CODE

B

R

ALTERNATOR

MAIN KEYSWITCH

2200 RPM

15A.

20

100

ENGINE

100

1

1

1

1

MAIN KEYSWITCH

F

R

F

R

W

C

B

C

B

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

'LOWER' SOL.

'RAISE' SOL.

'LOWER' SOL.

'RAISE' SOL.

NO MATERIAL FLOW AUDIBLE ALARM

ASSIST SOL.(OPT)

'LOWER' SOL.

'RAISE' SOL.

'RELEASE' SOL.

'ENGAGE' SOL.

VIBRATOR SOL.

BACKUP ALARM (OPTIONAL)

BRAKE RELEASE SOL.

RH TRACTION EDC

LH TRACTION EDC

LOCK SOL.

RANGE SOL.

FWD SOL.

100

NOTE: SEE SHEET 1 OF 2 FOR REMAINDER OF SCHEMATIC

4494-105-21 Page 2 of 4 11/04

452/552 Paver Electrical Schematic 9704-417-36, 9704-417-55a, 9704-417-54a

4

4

15A.

4

4 50A.

BURNER

15A.

45

245

SCREED

15A.

F/G/S

30A.

GATES

NOTE: WIRE 45 SAME AS 46 ON SCREED ONLY!

4

SPRAYDOWN

4

47

117A

115

115

115

115

115

115

115

115

115

45

45

45

45

47

(C)

(C)

150

165A

167A

167A

165A

45

3

106

K18

K16

3

98

89

88

157A 5

155A 4

150

8

LAI

6

3

1

DEC

INC

157

155

157

155

LH AUTO ISOLATION RELAY

167A

165A

5

4

160

RAI

6

3

1

DEC

INC

167

165

167

165

RH CONVEYOR CONTROL

10 PIN RECEPTACLE FOR AUTO CABLE

162

8

RH AUTO ISOLATION RELAY

117

ON

FUEL PUMP OFF

ON

FAN NO.4 OFF

ON

FAN NO.3 OFF

ON

FAN NO.2 OFF

ON

FAN NO.1 OFF

ON

148

146

138

136

128

126

118

116

117

148

GLOW PLUG NO.4

146

RH EXT. BURNER (NO.4)

138

GLOW PLUG NO.3

136

LH EXT. BURNER (NO.3)

128

GLOW PLUG NO.2

126

RH MAIN BURNER (NO.2)

118

GLOW PLUG NO.1

116

LH MAIN BURNER (NO.1)

117

DEC. SOL.

INC. SOL.

DEC. SOL.

INC. SOL.

R

RH NO FLOW

CRFA

R

LH NO FLOW

R.H. GATE MOTOR

L.H. GATE MOTOR

FUEL PUMP MOTOR

GLOW PLUG NO.4

FAN MOTOR NO.4

GLOW PLUG NO.3

FAN MOTOR NO.3

GLOW PLUG NO.2

FAN MOTOR NO.2

GLOW PLUG NO.1

FAN MOTOR NO.1

FUEL PUMP MOTOR

STANDARD FUEL OIL BURNER CONTROL FUEL PUMP OFF

117

OPTIONAL FOR NON-FUEL OIL HEATING

MAN

SET

160

RED

106

102

RH AUTOMATIC SCREED CONTROL AUTO

162

K17

K18

K15

RED

10 PIN RECEPTACLE FOR AUTO CABLE

152

MAT THICKNESS (TOWPOINT)

157A

155A

157A

155A

45

3

MAN

SET

AUTO

MAT THICKNESS (TOWPOINT)

105

YEL

101

YEL

102

HORN

HORN SW.

LH AUTOMATIC SCREED CONTROL

OPENS WITH MATERIAL PRESENT

152

3

(B) 98

RH FLOW SWITCH (A)

105

101

K16

18

19

MATERIAL FLOW INDICATORS AND FLOW ALARM RELAY

K17

K15

18

19

(B) 88

OPENS WITH MATERIAL PRESENT

(A)

LH FLOW SWITCH

100

100

100

100

JUMPER

J

I

H

G

F

E

D

C

B

A

J

I

H

G

F

E

D

C

B

A

K3

K3

HORN RELAY

100

100

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

45

45

45

45

45

45

45

45

47

45

46

46

46

46

46

47

46

46

46

RH SLOPE

LH SLOPE

5 PIN

46

MAIN CROWN

RH MATCH HEIGHT

LH MATCH HEIGHT

RH EXT (CONSOLE)

RH EXTEND

LH EXT. (CONSOLE)

12 11 10 9 8 7 6 5 4 3 2 1

E

D

GND +8V SIG. GND

C D E

DECREASE

INCREASE

DECREASE

INCREASE

DECREASE

INCREASE

DOWN

UP

DOWN

UP

OUT

IN

OUT

IN

OUT

IN

OUT

IN

51

B

E

D

B

91 90

C

D

81

A

D

A

C

80

E

A

+8V

SIG.

GND

GND

+14V

D

C

81 80

C

B

FEEDER CONTROL

FEEDER CONTROL`

46

53

54

93

91

90

47

3

80

81

83

52

46

GND

SIG.

+8V

GND

+14V

184

183

174

173

190

189

186

185

176

175

184

183

174

173

182

181

172

171

SCREED CONTROLS

GENERATION III

+14V

A

53

54

54

51

E

B

10 PIN

5 PIN

AUTO

OFF

OVERRIDE

STOP

RH FEED

D

OVERRIDE

REMOTE FEED

LH EXTEND

47

AUTO

OFF

FEED INTERFACE MODULE

46

46

OVERRIDE

STOP

LH FEED

C

REMOTE FEED

1KQ 1/2W. C

A B

WAND

52

D

52

D

C

C

E

C

B

B

B

A

A

A

GENERATION III LH CONVEYOR CONTROL

OVERRIDE

SONIC

CONTINUED FROM PAGE 1 OF SCHEMATIC

E

D

C

B

A

3

A

E

D

C

B

E

D

C

B

A

E

D

C

B

A

93

D

C

C

B

B

B

WAND

SONIC

1KQ 1/2W.

A

A

DEC. SOL.

INC. SOL.

DOWN SOL.

UP SOL.

DOWN SOL.

UP SOL.

OUT SOL.

IN SOL.

OUT SOL.

IN SOL.

DEC. SOL.

INC. SOL.

DEC. SOL.

INC. SOL.

STOP

97

STOP

87

5 PIN

A

5 PIN

10 PIN

83

+8V

SIG.

GND

GND

+14V

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

RH FEED EDC

LH FEED EDC

4494-105-21

Page 3 of 4

11/04

452/552 Paver Electrical Schematic 9704-417-36, 9704-417-55a, 9704-417-54a

C

D

ENGINE

113A 103

K15 100 3 3

101 K16

100 3 3

102 107

K17 100 3 3

105 108

K18 100 3 3

106

K15

10

7.5

10

7.5

10

5

7.5

5

FEED INTERFACE MODULE

K16

2

K17

4

K2

K1

K18

15

SPARE

17

E

291 292 294 295 296 297 331 332 245

TO BATTERY POSITIVE 20 1 4

#21 TO T.B. #1 TO STARTER

VIEW B-B

115

1

B

A

A D

STARTER

B C

OFF

291 292 294 295 296 297 331 332 245

ON

281 282 284 285 286 287

115

100

VIEW C-C

281 282 284 285 286 287

BATTERY

VIEW E-E

K6

51 52 83 81 80 3 47 90 91 93 54 53

VIEW A-A

SCREED

104

K5

OFF

G J F A B C E D

REAR

3

K3

PUSH ON - PULL OFF

115

114

CIRCUIT BREAKERS

POWER ON

H

100

3

50 BURNER

113A

K6

30 GATES

RIGHT

113

15 FLASHERS

109A

110 109A

15 LIGHTS

117A

18

15 SPRAYDOWN

46

K5

15 F/G/S

245

109

15 CONSOLE

45

100

15 SCREED

LEFT

E

19

15 ENGINE

FRONT

K3

ENGINE

100

GRID HEAT

MEGA 125A

2

3A 3C 5 6 7 8 9 10 11 15 17 18 19 21 21A 21B 22 24 25 27 28 29 30 33 34 35 36 37 42 45 46 46 46 46 47 48 49 50 51 52 53 54 61 62 63 64 65 66 70 71 73 74 77 78 79 80 81 83 87 88 90 91 93 97 98 101 102 103 104 105 106 107 108 109 110 110 113 114 117 117A 155 157 165 167 173 174 183 184

20

2

3A 3C 5 6 7 8 9 10 11 15 17 18 19 21 21A 21B 22 24 25 27 28 29 30 33 34 35 36 37 42 45 46 46 46 46 47 48 49 50 51 52 53 54 61 62 63 64 65 66 70 71 73 74 77 78 79 80 81 83 87 88 90 91 93 97 98 101 102 103 104 105 106 107 108 109 110 110 113 114 117 117A 155 157 165 167 173 174 183 184

1

MEGA 125A

VIEW D-D 4494-105-21

Page 4 of 4

11/04

452/552 Paver Electrical Schematic 9704-417-36, 9704-417-55a, 9704-417-54a

4494-105-22

Page 1 of 4

11/04

462/562 Paver Electrical Schematic 9704-417-39b, 9704-417-56a, 9704-417-54a

100

NOTE: SEE SHEET 1 OF 2 FOR REMAINDER OF SCHEMATIC

4494-105-22 Page 2 of 4 11/04

462/562 Paver Electrical Schematic 9704-417-39b, 9704-417-56a, 9704-417-54a

4

NOTE: WIRE 45 SAME AS 46 ON SCREED ONLY!

15A.

4

4 50A.

BURNER

15A.

45

45

45

45

115

115

115

115

115

115

115

115

115

117A

45

245

SCREED

15A.

F/G/S

30A.

SPRAYDOWN

4

4

4

GATES

A

J

I

H

G

F

E

D

C

B

A

J

I

H

G

F

E

D

C

B

(C)

(C)

150

ON

FAN NO.4 OFF

ON

FAN NO.3 OFF

ON

FAN NO.2 OFF

ON

FAN NO.1 OFF

ON

148

146

138

136

128

126

118

116

117

117

165A

167A

167A

165A

45

3

RED 106

K18

3

98

89

88

157A

155A

5

4

150

8

LAI

6

3

1

DEC

INC

157

155

157

155

LH AUTO ISOLATION RELAY

167A

165A

5

4

160

8

RAI

6

3

1

DEC

INC

167

165

167

165

RH AUTO ISOLATION RELAY

10 PIN RECEPTACLE FOR AUTO CABLE

162

ON

FUEL PUMP OFF

148

GLOW PLUG NO.4

146

RH EXT. BURNER (NO.4)

138

GLOW PLUG NO.3

136

LH EXT. BURNER (NO.3)

128

GLOW PLUG NO.2

126

RH MAIN BURNER (NO.2)

118

GLOW PLUG NO.1

116

LH MAIN BURNER (NO.1)

117

DEC. SOL.

INC. SOL.

DEC. SOL.

INC. SOL.

R

RH NO FLOW

CRFA

R

LH NO FLOW

R.H. GATE MOTOR

L.H. GATE MOTOR

FUEL PUMP MOTOR

GLOW PLUG NO.4

FAN MOTOR NO.4

GLOW PLUG NO.3

FAN MOTOR NO.3

GLOW PLUG NO.2

FAN MOTOR NO.2

GLOW PLUG NO.1

FAN MOTOR NO.1

FUEL PUMP MOTOR

STANDARD FUEL OIL BURNER CONTROL

117

OPTIONAL FOR NON-FUEL OIL HEATING

MAN

SET

160

K17

106

102

RH AUTOMATIC SCREED CONTROL AUTO

162

K15 K18

RED

K16

10 PIN RECEPTACLE FOR AUTO CABLE

152

MAT THICKNESS (TOWPOINT)

157A

155A

157A

155A

45

3

MAN

SET

AUTO

MAT THICKNESS (TOWPOINT)

105

YEL

101

YEL

102

HORN

HORN SW.

LH AUTOMATIC SCREED CONTROL

OPENS WITH MATERIAL PRESENT

152

3

(B) 98

RH FLOW SWITCH (A)

105

101

K16

18

19

MATERIAL FLOW INDICATORS AND FLOW ALARM RELAY

K17

K15

18

19

(B) 88

OPENS WITH MATERIAL PRESENT

(A)

LH FLOW SWITCH

100

100

100

100

FUEL PUMP OFF

JUMPER

47

47

K3

HORN RELAY

100

100

K3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

45

45

45

45

45

45

45

45

45

46

46

46

46

46

46

46

STOP

5 PIN

46

RH EXT (CONSOLE)

RH EXTEND

LH EXT (CONSOLE)

LH EXTEND

RH SLOPE

MAIN CROWN

RH MATCH HEIGHT

12 11 10 9 8 7 6 5 4 3 2 1

E

D

C

B

A

E

GND +8V SIG. GND

C D E

51

B

E

D

B

91 90

C

D

81

A

D

A

C

80

E

A

+8V

SIG.

GND

GND

+14V

D

C

81 80

C

B

FEEDER CONTROL

FEEDER CONTROL`

46

53

54

93

91

90

47

3

80

81

83

52

46

GND

SIG.

+8V

GND

+14V

A

DECREASE

INCREASE

DOWN

UP

DOWN

UP

OUT

IN

OUT

IN

OUT

IN

OUT

IN

DECREASE

INCREASE

DECREASE

INCREASE

184

183

174

173

190

189

186

185

176

175

184

183

174

173

182

181

172

171

SCREED CONTROLS

3

E

D

C

A

E

D

C

B

E

D

C

B

A

E

D

C

B

A

93

D

C

C

B

B

B

WAND

SONIC

1KQ 1/2W.

A

A

DEC. SOL.

INC. SOL.

DOWN SOL.

UP SOL.

DOWN SOL.

UP SOL.

OUT SOL.

IN SOL.

OUT SOL.

IN SOL.

DEC. SOL.

INC. SOL.

DEC. SOL.

INC. SOL.

STOP

97

STOP

87

5 PIN

A

5 PIN

10 PIN

83

+8V

SIG.

GND

GND

+14V

B

GENERATION III RH CONVEYOR CONTROL

+14V

A

53

54

54

51

52

52

E

D

C

B

A

B

10 PIN

5 PIN

AUTO

OFF

OVERRIDE

STOP

RH FEED

D

OVERRIDE

REMOTE FEED

FEED INTERFACE MODULE

46

AUTO

OFF

OVERRIDE

C

LH FEED 46

LH SLOPE

47

C

C

OVERRIDE

B

B

D

A

GENERATION III LH CONVEYOR CONTROL A

REMOTE FEED

1KQ 1/2W.

WAND

SONIC

LH MATCH HEIGHT

47

CONTINUED FROM PAGE 1 OF SCHEMATIC

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

RH FEED EDC

LH FEED EDC

4494-105-22

Page 3 of 4

11/04

462/562 Paver Electrical Schematic 9704-417-39b, 9704-417-56a, 9704-417-54a

C

D

ENGINE

3

K5

113A 103

K15 100 3 3

101 K16

100 3 3

102 107

K17 100 3 3

105 108

K18 100 3 3

106

7.5

10

7.5

10

5

7.5

5

FEED INTERFACE MODULE

K16

2

K17

4

K2

K1

K18

15

SPARE

17

E

291 292 294 295 296 297 331 332 245

TO BATTERY POSITIVE 20 1 4

#21 TO T.B. #1 TO STARTER

VIEW B-B

115

1

B

A

A D

STARTER

B C

OFF

291 292 294 295 296 297 331 332 245

OFF

H G J F A B C E D

ON

281 282 284 285 286 287

115

100

VIEW C-C

281 282 284 285 286 287

BATTERY

VIEW E-E

K15

10

SCREED

104

K6

51 52 83 81 80 3 47 90 91 93 54 53

PUSH ON - PULL OFF

115

K3

POWER ON

VIEW A-A

REAR

114

CIRCUIT BREAKERS

100

3

50 BURNER

113A

K6

30 GATES

RIGHT

113

15 FLASHERS

109A

110 109A

15 LIGHTS

117A

18

15 SPRAYDOWN

245

K5

15 F/G/S

46

109

15 CONSOLE

45

19 100

15 SCREED

LEFT

E

15 ENGINE

FRONT

K3

ENGINE

100

GRID HEAT

MEGA 125A

2

3A 3C 5 6 7 8 9 10 11 15 17 18 19 21 21A 21B 22 24 25 27 28 29 30 33 34 35 36 37 42 45 46 46 46 46 47 48 49 50 51 52 53 54 61 62 63 64 65 66 70 71 73 74 77 78 79 80 81 83 87 88 90 91 93 97 98 101 102 103 104 105 106 107 108 109 110 110 113 114 117 117A 155 157 165 167 173 174 183 184

20

2

3A 3C 5 6 7 8 9 10 11 15 17 18 19 21 21A 21B 22 24 25 27 28 29 30 33 34 35 36 37 42 45 46 46 46 46 47 48 49 50 51 52 53 54 61 62 63 64 65 66 70 71 73 74 77 78 79 80 81 83 87 88 90 91 93 97 98 101 102 103 104 105 106 107 108 109 110 110 113 114 117 117A 155 157 165 167 173 174 183 184

1

MEGA 125A

VIEW D-D 4494-105-22

Page 4 of 4

11/04

462/562 Paver Electrical Schematic 9704-417-39b, 9704-417-56a, 9704-417-54a

4494-105-23

Page 1 of 4

11/04

452/552 Remix Paver Electrical Schematic 9704-417-41, 9704-417-43b, 9704-417-45d

4494-105-23

Page 2 of 4

11/04

452/552 Remix Paver Electrical Schematic 9704-417-41, 9704-417-43b, 9704-417-45d

4494-105-23

Page 3 of 4

11/04

452/552 Remix Paver Electrical Schematic 9704-417-41, 9704-417-43b, 9704-417-45d

LEFT HAND

RIGHT HAND

4494-105-23

Page 4 of 4

11/04

452/552 Remix Paver Electrical Schematic 9704-417-41, 9704-417-43b, 9704-417-45d

4494-105-24

Page 1 of 4

11/04

462/562 Remix Paver Electrical Schematic 9704-417-42a, 9704-417-44a, 9704-417-45d

4494-105-24

Page 2 of 4

11/04

462/562 Remix Paver Electrical Schematic 9704-417-42a, 9704-417-44a, 9704-417-45d

4494-105-24

Page 3 of 4

11/04

462/562 Remix Paver Electrical Schematic 9704-417-42a, 9704-417-44a, 9704-417-45d

LEFT HAND

RIGHT HAND

4494-105-24

Page 4 of 4

11/04

462/562 Remix Paver Electrical Schematic 9704-417-42a, 9704-417-44a, 9704-417-45d

4494-105-29

Page 1 of 4

11/04

452/552 Remix Paver Electrical Schematic 9704-417-59a, 9704-417-43b, 9704-417-45d

4494-105-29

Page 2 of 4

11/04

452/552 Remix Paver Electrical Schematic 9704-417-59a, 9704-417-43b, 9704-417-45d

4494-105-29

Page 3 of 4

11/04

452/552 Remix Paver Electrical Schematic 9704-417-59a, 9704-417-43b, 9704-417-45d

LEFT HAND

RIGHT HAND

4494-105-29

Page 4 of 4

11/04

452/552 Remix Paver Electrical Schematic 9704-417-59a, 9704-417-43b, 9704-417-45d

4494-105-30

Page 1 of 4

5/04

462/562 Remix Paver Electrical Schematic 9704-417-60a, 9704-417-44a, 9704-417-45d

4494-105-30

Page 2 of 4

5/04

462/562 Remix Paver Electrical Schematic 9704-417-60a, 9704-417-44a, 9704-417-45d

4494-105-30

Page 3 of 4

5/04

462/562 Remix Paver Electrical Schematic 9704-417-60a, 9704-417-44a, 9704-417-45d

LEFT HAND

RIGHT HAND

4494-105-30

Page 4 of 4

5/04

462/562 Remix Paver Electrical Schematic 9704-417-60a, 9704-417-44a, 9704-417-45d

A Terex Company

4495-001

12/00

Page 1 of 3 CR451/CR551 Remix Pavers Hydraulic Schematic 9704-662-33 Cedarapids Inc.

A Terex Company

4495-001

12/00 Page2 of 3

A Terex Company

4495-001

12/00 Page3 of 3

A Terex Company

4495-002

12/00

Page 1 of 3 CR461/CR561 Remix Pavers Hydraulic Schematic 9704-662-34 Cedarapids Inc.

A Terex Company

4495-002

12/00 Page2 of 3

A Terex Company

4495-002

12/00 Page3 of 3

A Terex Company

4495-003

12/00

Page 1 of 3 CR461R/CR561R Remix Pavers Hydraulic Schematic 9704-662-35 Cedarapids Inc.

A Terex Company

4495-003

12/00 Page2 of 3

A Terex Company

4495-003

12/00 Page3 of 3

A Terex Company

4495-004

11/00

Page 1 of 1 Stretch Screeds Hydraulic Schematic 9704-662-36 Cedarapids Inc.

A Terex Company

4495-005

11/00

Page 1 of 1 Fixed Screeds Hydraulic Schematic 9704-662-37 Cedarapids Inc.

4495-006

11/04

Page 1 of 2 MS-4 Electrical Schematic 9702-200-09d & MS-4 Hydraulic Schematic 9702-050-46b Cedarapids Inc.

4495-006

11/04 Page2 of 2

V1 U1

V2 U2

GROUND BAR

W1

W2

34 KVA GENERATOR 208Y/120V-3PH-60HZ 208V (L-L) 120V (L-N)

N

L3

L2

L1

V-F-A

GND

N

N

N

N

N

N

METER (1) (4)

GND

GND

GND

100

100

100

100

100

100

100

100

100

V2

T2 30 T3 AMP

L2 L3

T2 30 T3 AMP

L2 L3

T2 30 T3 AMP

L2 L3

30 T3 AMP L3

T3

T2

5L1

5L3

5L2

5L1

4L3

4L2

4L1

3L3

3L2

3L1

2L3

2L2

2L1

1L3

1L2

1L1

113

112

111

123

122

121

133

132

131

MAN

OFF

AUTO

143

142

141

CT5

HEATER POWER LED

1 L1

C1 2 T1

10AWG/4c

1H1

BLACK

C4

GREEN

BLACK

LOAD

N

N

WHITE

143

OT2 OT1 IN + - + - + 7 6 5 4 3 2 1

PWR 8

133

OT2 OT1 IN + - + - + 7 6 5 4 3 2 1

PWR 8

123

OT2 OT1 IN + - + - + 7 6 5 4 3 2 1

PWR 8

113

OT2 OT1 IN + - + - + 7 6 5 4 3 2 1

PWR 8

BLACK

A1

A1

A1

A1

C4

C3

C2

C1

LOAD

LINE

BLACK

A2

TEMP SENSOR 100 ohm RTD

A2

TEMP SENSOR 100 ohm RTD

A2

TEMP SENSOR 100 ohm RTD

A2

TEMP SENSOR 100 ohm RTD

N

WHITE

N

GREEN

LOAD

LINE

N

N

N

N

N

WHITE

N

GREEN

GFCI OUTLET 120V-20A GND

GND

RED

WHITE

BLACK

GREEN

RED

WHITE

BLACK

5L2

10AWG/4c

4H3

4H2

4H1

GND

3H3

3H2

3H1

GREEN

RED

WHITE

BLACK

GREEN

RED

GFCI OUTLET 120V-20A GND GREEN

RH EXT. HEAT CONTROL

N

4 T2

2 T1

10AWG/4c

10AWG/4c

GND

2H3

2H2

2H1

GND

1H3

5L2 LINE

RH MAIN HEAT CONTROL

N

4 T2

2 T1

6 T3 37 AMP

LH MAIN HEAT CONTROL

N

C3

6 T3 37 AMP

LH EXT. HEAT CONTROL

N

4 T2

2 T1

6 T3 37 AMP

C2

6 T3 37 AMP

4 T2

WHITE

GFCI OUTLET 120V-20A GND

5 L3

3 L2

1 L1

5 L3

3 L2

1 L1

5 L3

3 L2

1 L1

5 L3

3 L2

1H2

5L3

10 AWG MTW

TEMPERATURE CONTROLLER

MAN

OFF

AUTO

CT4

HEATER POWER LED

10 AWG MTW

TEMPERATURE CONTROLLER

MAN

OFF

AUTO

CT3

HEATER POWER LED

10 AWG MTW

TEMPERATURE CONTROLLER

MAN

OFF

AUTO

CT2

10 AWG MTW

TEMPERATURE CONTROLLER

3A

CONTROL

L3 20A

CB7

L2 20A

CB6

L1 20A

T1

T2

L2

CB5

T1

L1

CB4

T1

L1

CB3

T1

L1

CB2

T1

L1

CB1

HEATER POWER LED

U2

POWER LUGS

W2

U1

V1

W1

BLK

H

F

E

C

H

F

E

C

GND

1L3

1L2

1L1

GND

1L3

1L2

1L1

H

F

E

C

H

F

E

BLK

GRN

RED

WHT

BLK

GRN

RED

WHT

H

F

E

C

H

F

E

C

HD30-18-8

GRN

RED

WHT

BLK

GRN

RED

WHT

BLK

C

GND

1L3

1L2

1L1

GND

1L3

1L2

1L1

GND

1L3

1L2

1L1

GND

1L3

1L2

1L1

HD30-18-8

GRN

RED

WHT

BLK

GRN

RED

N

L3

L2

L1

WHT

L3

1 2

GND

L2

CT1 100:5

N

L1

20 KVA GENERATOR 208Y/120V-3PH-60 HZ 208V (L-L) 120V (L-N)

1L3

1L1

RH EXTENDER

1L1

RH MAIN

1L1

LH MAIN

1L1

LH EXTENDER

1L1

1L1

1L2

1L3

1L2

1L3

1L2

1L3

1L2

1L3

1L2

1L3

1L2

1L3

OPTIONAL EXTENSION

1L2

1L3

1L2

1L3

1L2

1L3

1L2

1L3

1L2

1L3

1L2

OPTIONAL EXTENSION

1L2

1L1

1L2

1L1

1L2

1L1

1L2

1L1

1L2

1L1

1L2

1L1

EXTENSION ELEMENTS (2) 450W 208V ON 14" (2) 900W 208V ON 26" (2) 1350W 208V ON 38"

RH EXTENDER ELEMENTS (2) 2.25KW 208V ON S20 (2) 1.8KW 208V ON S16

RH MAIN SCREED ELEMENTS (2) 2.25KW 208V ON S20 (2) 1.8KW 208V ON S16

LH MAIN SCREED ELEMENTS (2) 2.25KW 208V ON S20 (2) 1.8KW 208V ON S16

LH EXTENDER ELEMENTS (2) 2.25KW 208V ON S20 (2) 1.8KW 208V ON S16

EXTENSION ELEMENTS (2) 450W 208V ON 14" (2) 900W 208V ON 26" (2) 1350W 208V ON 38"

A Terex Company

4495-007 Page 1 of 2 Stretch Electric Screed Electrical Schematic 9704-611-55 & Stretch Electric Screed Hydraulic Schematics 9704-662-58 Stretch 16 9704-662-56 Stretch 20 Cedarapids Inc.

7/02

A Terex Company TRACTOR

SCREED

MOTOR 2.14 CID X

P

S S S

B

M

13/64"

17 GPM

1800 RPM

M

P

Stretch 16

M

400 PSI STANDBY 5000 PSI

4000 PSI COMPENSATOR

T

T VALVE BLOCK

T

ADJUST NEEDLE VALVE TO ACHIEVE DESIRED MOTOR SPEED

S

L

PUMP 2.75 CID FILTER

PUT JUMPER HOSE BETWEEN PORTS M2 AND X ON PUMP

TRACTOR

SCREED

1800 RPM P 22 GPM

S S S

M

13/64"

M

P X

M

.063"

Stretch 20

B 5000 PSI

300 PSI

400 PSI

T

T VALVE BLOCK M2

ADJUST NEEDLE VALVE TO ACHIEVE DESIRED MOTOR SPEED

T MOTOR 2.8 CID

4500 PSI

M4

PUMP 3.48 CID

S

L1,L2

STRAINER

4495-007

7/02 Page 2 of 2

4495-008

Page 1 of 2 452/552 and 462/562 Paver Hydraulic Schematic 9704-662-63c

11/04

4495-008

Page 2 of 2 452/552 and 462/562 Paver Hydraulic Schematic 9704-662-63c

11/04

4495-009

Page 1 of 3

452/552 and 462/562 Remix Paver Hydraulic Schematic 9704-662-64

11/04

4495-009

Page 2 of 3

452/552 and 462/562 Remix Paver Hydraulic Schematic 9704-662-64

11/04

4495-009

Page 3 of 3

452/552 and 462/562 Remix Paver Hydraulic Schematic 9704-662-64

11/04

4495-011

Page 1 of 2

7/03

Fastach II - Electrical & Hydraulic Schematics 9704-611-46b, 9704-662-58, 9704-662-97

TRACTOR

SCREED

MOTOR 2.14 CID X

P

M

13/64"

17 GPM B

S S S

1800 RPM

M

P

M

400 PSI STANDBY 5000 PSI

4000 PSI COMPENSATOR

Generator Drive Hydraulics 9704-662-58

T

T VALVE BLOCK

T

ADJUST NEEDLE VALVE TO ACHIEVE DESIRED MOTOR SPEED

L

S

PUMP 2.75 CID FILTER

Screed Hydraulics 9704-662-97

4495-011

Page 2 of 2

7/03

Fastach II - Electrical & Hydraulic Schematics 9704-611-46b, 9704-662-58, 9704-662-97

RH TRACTION

RH CONVEYOR 33.6 GPM MAX

33.6 GPM MAX

50.4 RATIO

230 RPM MAX.

390 PSI

29.9

2500 RPM

48.0 CID 2.8

CID 2.8

CID

4.88

CID

1.4 CID

1.61 CID MINIMUM

CID 4WD VALVE

10

b

.078" DIA. ORIFICES

m 2

FILTER

PARKING BRAKE

IDLE

DIFFERENTIAL LOCK VALVE RANGE SHIFT

OPTIONAL FRONT WHEEL ASSIST TIRE PAVERS ONLY

TIRE PAVERS ONLY

FULL 4WD PILOT VALVE

RH TRACTION DRIVE

LH TRACTION DRIVE

THROTTLE CYLINDER

CHARGE PRESSURE

THROTTLE VALVE

LH TRACTION

LH CONVEYOR 33.6 GPM MAX

230 RPM MAX.

B 390 PSI

29.9

2500 RPM

CID

4WD VALVE 4.88 CID

2.8

2.8 CID

1.61 CID MINIMUM

CID

1.4 CID

48.0 CID 50.4 RATIO

10

b

m 2

FILTER

33.6 GPM MAX

4495-012

Page 1 of 2 352 and 362 Paver Hydraulic Schematic 9704-663-02

9/03

HOPPER WINGS TRUCK HOOK (OPTIONAL)

LH GRADE (OPTIONAL)

175 PSI NITROGEN PRECHARGE

RH GRADE (OPTIONAL)

OPTIONAL SCREED ASSIST (SUPPLIED WITH EXTENDABLE)SCREED)

UP SCREED LIFT

FRAME RAISE

E

STEERING

UP

TIRE PAVERS ONLY

REPHASE PORT AT EACH END OF CYLINDER STROKE

V A

D

STEERING VALVE

900 PSI T

I TO SCREED VALVES P

P

T

T

8.1 GPM MAX

FROM SCREED VALVES

AUXILIARY PUMP SUPERCHARGE FILTER 2050 RPM

SCREED VIBRATORS FLOW FROM SCREED VIBRATORS

REPHASE PORT CROSS SECTION

2250 PSI PRECHARGE

.913 CID LH

1500 PSI 5

m

2500 PSI

b2

FLOW TO SCREED VIBRATORS

15 PSI 2250 PSI PRECHARGE FUME FAN

.659 CID

RH

HOOD RAISING SYSTEM

4550 RPM TRACK TENSIONING TRACK PAVERS ONLY

2800 PSI

COOLING FAN VALVE 10.7 GPM

12VDC 2

2130 RPM 1.16 CID

2.1 GPM MAX COOLER

1

23.5 GPM

900 PSI

COOLING FAN 2800 RPM MAX 2400 ACTUAL

3000 PSI MAX

1.94 CID

2.55 CID 3

12VDC 10

b

m 2

FILTER

4495-012

Page 2 of 2 352 and 362 Paver Hydraulic Schematic 9704-663-02

9/03

4495-013

Page 1 of 2

10/04

Fastach II - Electrical & Hydraulic Schematics 9704-611-80, 9704-662-56, 9704-663-24

Generator Drive Hydraulics 9704-662-56

Screed Hydraulics 9704-663-24

4495-013

Page 2 of 2

10/04

Fastach II - Electrical & Hydraulic Schematics 9704-611-80, 9704-662-56, 9704-663-24

4495-014

Page 1 of 3

452/552 and 462/562 Remix Paver Hydraulic Schematic 9704-663-31

12/04

4495-014

Page 2 of 3

452/552 and 462/562 Remix Paver Hydraulic Schematic 9704-663-31

12/04

4495-014

Page 3 of 3

452/552 and 462/562 Remix Paver Hydraulic Schematic 9704-663-31

12/04

24 Hour Service Number (800) 821-5600