• Chapter 1 Introduction
  • Nomenclature Cross-Reference List
  • Section Ii. Equipment Description And Data
  • 1.11 Diesel Engine.
  • 1.12 Pump Drive Gearbox
  • 1.13 Hydraulic Propulsion Pumps
  • 1.15 Auger/Conveyor Motor.
  • 1.16 Screed Vibration Motors.
  • 1.17 Hydraulic Propulsion Motor.
  • 1.19 Stack Valve.
  • 1.20 Relief Valves
  • 1.21 50/50 Flow Divider
  • 1.22 Control Handles
  • 1.24 Radiator Assembly
  • 1.25 Track Suspension Assembly
  • 1.26 Frame Components
  • 1.27 Auger/Conveyor Assemblies
  • 1.27.1 Conveyor Assembly.
  • 1.27.2 Auqer Assembly.
  • B. Two Foot Auger And Fender Extension
  • 1.28 Main Screed Components
  • A. Screed Tow Point
  • Fuel Injectors
  • Main Screed Vibration Motor
  • 2.1 General Maintenance Procedures
  • Section I. Repair Parts; Tools; Special Tools; Test, Measurement And Diagnostic Equipment (Tmde); And Support Equipment
  • Section Ii. Troubleshooting
  • 2.5.1 Malfunction Symptom Index
  • 1. Engine Fails To Start Or Fails To Start Easily
  • Table 2-1. Engine Troubleshooting - Continued.
  • 1. Engine Fails To Start Or Fails To Start Easily Continued
  • Table 2-1. Engine Troubleshooting - Continued
  • Table 2-1. Engine Troubleshooting - Continued
  • Table 2-1. Engine Troubleshooting - Continued.
  • Table 2-1. Engine Troubleshooting - Continued
  • Table 2-1. Engine Troubleshooting - Continued.
  • 5. High Oil Pressure
  • Table 2-1. Engine Troubleshooting - Continued
  • Table 2-1. Engine Troubleshooting - Continued.
  • Table 2-1. Engine Troubleshooting - Continued.
  • 9. Poor Compression
  • Table 2-2. Track Tension Troubleshooting.
  • Table 2-2. Track Tension Troubleshooting - Continued
  • Table 2-2. Track Tension Troubleshooting - Continued
  • 3. Auxiliary Hydraulic Supply To Vibration And Cylinder Circuits Faulty
  • Table 2-3. Propulsion System Troubleshooting
  • Table 2-3. Propulsion System Troubleshooting - Continued
  • Table 2-3. Propulsion System Troubleshooting - Continued
  • Table 2-3. Propulsion System Troubleshooting - Continued
  • Table 2-3. Propulsion System Troubleshooting - Continued
  • Table 2-3. Propulsion System Troubleshooting - Continued
  • Table 2-3. Propulsion System Troubleshooting - Continued.
  • Table 2-3. Propulsion System Troubleshooting - Continued.
  • Table 2-3. Propulsion System Troubleshooting - Continued
  • 4. Mistracking
  • 5. No Hydraulic Functions
  • Table 2-4. Tow Point Lift System Troubleshooting
  • 2. One Tow Point Cylinder Fails To Operate
  • Table 2-4. Tow Point Lift System Troubleshooting - Continued
  • Table 2-5. Screed Lift System Troubleshooting
  • Table 2-5. Screed Lift System Troubleshooting - Continued
  • 2. Screed Fails To Lower
  • Table 2-5. Screed Lift System Troubleshooting - Continued
  • 2.11 Hopper Lift System
  • 1. Hopper Fails To Operate
  • Table 2-6. Hopper Lift System Troubleshooting - Continued
  • Table 2-6. Hopper Lift System Troubleshooting - Continued
  • Table 2-6. Hopper Lift System Troubleshooting - Continued
  • Table 2-6. Hopper Lift System Troubleshooting - Continued
  • Table 2-7. Auger/Conveyor System Troubleshooting
  • Table 2-7. Auger/Conveyor System Troubleshooting - Continued
  • Table 2-7. Auger/Conveyor System Troubleshooting - Continued
  • Table 2-7. Auger/Conveyor System Troubleshooting - Continued
  • Table 2-7. Auger/Conveyor System Troubleshooting - Continued
  • Table 2-7. Auger/Conveyor System Troubleshooting - Continued
  • Table 2-8. Vibration System Troubleshooting
  • Table 2-8. Vibration System Troubleshooting - Continued
  • Table 2-8. Vibration System Troubleshooting - Continued
  • Table 2-8. Vibration System Troubleshooting - Continued
  • Table 2-8. Vibration System Troubleshooting - Continued
  • Table 2-8. Vibration System Troubleshooting - Continued
  • Table 2-8. Vibration System Troubleshooting - Continued
  • Table 2-9. Screed Extension System Troubleshooting
  • Table 2-9. Screed Extension System Troubleshooting - Continued
  • Table 2-9. Screed Extension System Troubleshooting - Continued
  • 2.15 Replace Cylinder Head Assembly
  • 1. Disconnect The Battery
  • 2. Remove Muffler Support Bracket
  • 5. Disconnect Wiring From Thermostat Housing
  • 6. Remove Valve Cover, Valve Cover Gasket, And Oil Breather Hose From Cylinder Head Assembly
  • 7. Remove Rocker Shaft Assembly And Push Rods From Cylinder Head Assembly
  • 9. Remove Cylinder Head Assembly From Engine Block
  • 10. Remove Lifting Brackets, Cylinder Head End Cover, Thermostat Housing, And Studs From Cylinder Head Assembly.
  • B. Clean
  • 1. Install Studs, Lifting Brackets, Cylinder Head End Cover, And Thermostat Housing To The Cylinder Head Assembly
  • C. Install Continued
  • 2. Install Cylinder Head Assembly Onto Engine Block.
  • C. Install - Continued
  • 3. Install Rocker Shaft Assembly And Push Rods Into Cylinder Head Assembly.
  • 5. Install Valve Cover, Valve Cover Gasket, And Oil Breather Hose To Cylinder Head Assembly
  • 6. Connect Wiring To Thermostat Housing.
  • C. Install Continued
  • 8. Install Fuel Lines
  • 10. Connect Battery.
  • Follow-On-Tasks
  • 2.16 Engine Replacement.
  • 1. Disconnect Batteries
  • 2. Remove Muffler Support Bracket
  • 4. Disconnect Electrical Connections From Alternator.
  • 5. Disconnect Electrical Connections From Thermostat Housing
  • A. Remove - Continued.
  • 2.16 Engine Replacement - Continued
  • 17. Loosen Clamp
  • 21. Remove Ground Wire G201
  • 22. Remove Knurled Nut
  • 25. Tag And Disconnect Harness Connectors
  • 26. Disconnect Throttle Control Cable From Fuel Injection Pump.
  • 27. Disconnect Fuel Lines From Fuel Lift Pump And Engine Fuel Filter
  • A. Remove Continued
  • 28. Drain Engine Oil And Disconnect Engine Oil Filter Hoses And Drain Hose From Engine.
  • 29. Disconnect Engine Oil Cooler Hoses.
  • 32. Disconnect Hydraulic Hoses From Auxiliary Vibration Pump
  • 33. Disconnect Hydraulic Hoses From Left Propulsion Pump
  • Plug Hose End And Cap Elbow
  • 34. Disconnect Hydraulic Hoses From Right Propulsion Pump
  • 35. Remove Hydraulic Charge Filters, Air Cleaners And Charge Filter Mounting Bracket
  • 37. Disconnect Engine And Pump Assembly From Mounts.
  • 2.16 Engine Replacement - Continued.
  • A. Remove Continued
  • I. Lower Engine And Pump Assembly
  • 38. Remove And Discard Shock Resilient Mounts From Engine, Flywheel Housing, And Pump Drive Gearbox  
  • 39. Remove Pump Drive Gearbox And Hydraulic Pumps, Drive Shaft, And Drive Plate.
  • H. Remove Hex Head Cap Screws  
  • A. Remove Continued
  • 40. Remove Front Engine Mounting Brackets, Oil Drain Hose, And Flywheel Housing Mounting Brackets From Engine.
  • B. Clean
  • 2. Wipe Off Dirt, Grease And Oil Residue From Pump Drive Gearbox
  • 5. Clean Threads Of Hex Head Cap Screws With Thread Locking Compound Solvent.
  • C. Install Continued
  • I. Install Lockwashers
  • 2. Remove Engine From Engine Stand And Place On Cribbing.
  • 3. Install Pump Drive Gearbox And Hydraulic Pumps, Drive Plate, And Drive Shaft Onto Engine.
  • E. Attach Chain Assembly
  • I. Install Lockwashers
  • C. Install - Continued.
  • 4. Install Shock Mounts Onto Engine, Flywheel Housing And Pump Drive Gearbox Mounts In Paving Machine
  • 5. Install Engine And Pump Assembly And Pump Drive Gearbox Into Engine Compartment Onto Shock Mounts And Engine Mounts
  • 2.16 Engine Replacement - Continued.
  • G. Align Mounting Holes In Front Engine Mounting Brackets
  • L. Coat Threads Of Hex Head Cap Screw  
  • O. Install Flat Washers
  • 6. Install Charge Filter Mounting Bracket, Air Cleaner, And Hydraulic Charge Filters  
  • C. Install - Continued
  • 8. Reconnect Hydraulic Hoses To Left Propulsion Pump
  • 9. Reconnect Hydraulic Hoses (144 And 146) To Auxiliary Vibration Pump
  • 2.16 Engine Replacement - Continued
  • 11. Reconnect Hydraulic Hose (142) To Auxiliary Vibration Pump And Hydraulic Hose (149) To Left Propulsion Pump.
  • 2.16 Engine Replacement - Continued
  • 12. Reconnect Engine Oil Cooler Hoses To Thermostat Housing And Engine Block Coolant Gallery.
  • C. Install - Continued.
  • 15. Install Throttle Control Cable Onto Fuel Injection Pump
  • 16. Reconnect Harness Connectors To Left And Right Forward Work Light Connectors
  • C. Install - Continued.
  • 19. Install Wire 150
  • 20. Install Ground Wire G201 Onto Hydraulic Reservoir Mounting Bracket
  • 24. Apply Electrical Insulating Compound To Induction Heater
  • 29. Apply Electrical Insulating Compound Onto End Of Harness Connectors
  • 30. Apply Electrical Insulating Compound Onto End Of Harness Connector  
  • 34. Apply Electrical Insulating Compound Onto Male Ends Of Fuel Shutoff Solenoid  
  • 35. Reconnect Electrical Connections To Thermostat Housing.
  • 36. Install Electrical Connections On Alternator
  • 37. Install Electrical Connections On Starter
  • 38. Install Clamps Onto Positive Battery Cable And Slave Cable.
  • 39. Install Muffler Support Bracket
  • 40. Reconnect Battery Cables Tobatteries
  • Follow-On-Tasks
  • 2.17 Diesel Engine Repair
  • 1. Remove Starter Assembly From Flywheel Housing
  • A. Remove - Continued.
  • A. Remove - Continued.
  • I. Use A Flat-Blade Screwdriver
  • S. Remove Gasket
  • 11. Remove Oil Sump, Dipstick, Drain Line Straight Adapter, And Oil Breather Hose From Engine Block
  • 2.17 Diesel Engine Repair - Continued
  • 12. Remove Balancer Unit From Engine Block.
  • B. Remove Hex Head Cap Screws
  • F. Use A Drive Pin Punch To Remove Spring Pin
  • 14. Remove Pistons And Connecting Rod Assemblies From Engine Block
  • 15. Remove Sleeve Bearings, Piston Rings, Gudgeon Pin, Sleeve Bushing, And Connecting Rod Assembly From Piston.
  • 16. Remove Flywheel And Flywheel Housing From Engine Block.
  • G. Attach Two Hex Head Screw Caps To Inner Most Flywheel Housing Lifter Holes
  • 17. Remove Thrust Washer, Camshaft, And Main Bearing Thimbles From Engine Block.
  • 18. Remove Rear Filler Block, Mae Bearing Caps, Main Sleeve Bearings Thrust Washer Bearings, Crankshaft Seal Housing, And Crankshaf Assembly From Engine Block.
  • 2.17 Diesel Engine Repair.
  • 19. Remove Piston Oil Pump Jets From Engine Block
  • B. Clean
  • C. Inspect
  • 3. Inspect Crankshaft Assembly Main Journals And Connecting Rod Journals For Wear And Ovality.
  • G. Use An Inside Caliper
  • 4. Inspect Thrust Washer Bearings And Main Sleeve Bearings For Wear
  • F. Gap Tolerance Table.
  • P. Visually Inspect Piston
  • 6. Inspect Cylinder Sleeves For Wear
  • G. Use An Outside Micrometer
  • 8. Inspect Balancer Unit Sleeve Bushings And Needle Bearings For Wear
  • D. Repair
  • B. Assemble Cylinder Head Assembly
  • D. Repair - Continued.
  • 2. Repair Rocker Shaft Assembly.
  • B. Assemble Rocker Shaft Assembly.
  • D. Repair - Continued
  • 3. Repair Engine Block By Replacement Of Cylinder Sleeves.
  • E. Use A Liner Puller Adapter
  • K. After Allowing New Cylinder Sleeves
  • 5. Repair Flywheel By Replacement Of Spur Gear
  • 6. Repair Balancer Unit By Replacement Of Sleeve Bushings And Needle Bearings.
  • D. Place Balancer Unit Frame
  • J. Use A Mandrel
  • 7. Repair Timing Gear By Replacement Of Bearing.
  • 8. Repair Camshaft Assembly By Replacement Of Bushing In Engine Block.
  • Engine Block
  • Pistons
  • Connecting Rod Assemblies
  • D. Repair - Continued
  • Crankshaft Assembly Regrind Data
  • Maximum Runout With Crankshaft Assembly Mounted On End Main Journals
  • Main Bearing Sleeves
  • Camshaft Thrust Washer
  • Valve Stem Guides.
  • Main Bearing Thimbles
  • Crankshaft Gear
  • Balancer Unit, Center Mounted
  • 1. Install Piston Oil Pump Jets And Align In Engine Block.
  • F. Install Main Sleeve Bearings
  • 1. Apply A Coating Of Gasket Sealing Compound To Surfaces Of Rear Filler Block
  • 3. Install Main Bearing Thimbles And Camshaft Into Engine Block
  • C. Lubricate Camshaft
  • 4. Install And Align Flywheel Housing On Engine Block
  • H. Measure Concentric Alignment Of Flywheel
  • 5. Install And Align Flywheel On Engine Block
  • G. Flywheel Trueing Must Be Within 0.012 In.
  • 6. Install Sleeve Bushing, Gudgeon Pin, Retaining Rings, Sleeve Bearings, And Connecting Rod Assemblies Onto Piston.
  • 7. Install Pistons And Connecting Rod Assemblies Into Engine
  • E. Install Connecting Rod Assembly
  • 8. Install Spur Gears, Balancer Unit Frame End, Oil Pump, Gear Shaft, Oil Relief Valve, And Timing Gear Onto Balancer Unit.
  • G. Lubricate Oil Relief Valve
  • 1. Lubricate Needle Bearings
  • X. Apply Thread Locking Compound
  • 9. Install Balancer Unit Into Engine
  • E. Install Flat Washers
  • 10. Install Oil Breather Hose, Drain Line Straight Adapter, Dipstick, And Oil Sump Onto Engine.
  • 11. Install Timing Gear Housing, Idler Gear Hub, Idler Gear, Camshaft Gear, Fuel Injection Pump Gear, Timing Gear Cover Seal, Timing Gear Cover, And Crankshaft Pulley Onto Engine
  • C. Apply A Thin Coating Of Gasket Sealing Compound
  • I. Install Idler Gear
  • 1. Install Woodruff Key
  • Q. Install Fuel Injection Pump Gear
  • U. Install Centering Tool Onto Crankshaft Assembly
  • Z. Apply Gasket Sealing Compound
  • E. Install - Continued
  • Section Iv. Fuel System Maintenance
  • A. Remove
  • 2.18 Replace/Repair Fuel Injectors And Lines - Continued
  • 2. Remove Fuel Injector
  • 1. Disassemble Fuel Injector
  • G. Flush Nozzle To Remove All Particles Of Carbon.
  • 3. Inspect Components
  • 4. Assemble Fuel Injector
  • I. Fuel Injector Pressure And Spray Test
  • 3. Back Leakage Test
  • 2. Install Fuel Lines
  • Follow-On-Tasks
  • 2.19 Replace/Repairfuel Injection Pump.
  • A. Remove
  • 2. Remove Fuel Injection Pump From Engine
  • B. Disassemble
  • 2. Remove Spring, Throttle Shaft, Spring Holder, Spring, Shutoff Bar, Shouldered Studs, Keep Plate, And Throttle Shaft
  • 3. Remove Governor Arm Assembly, Metering Valve, And Spring Link
  • 4. Remove Fluid Passage Bolt, Cap Nut, Auto Advance Piston Housing Assembly, Gasket, And Stud
  • 6. Loosen Screw And Remove Fuel Banjo Bolts, Fluid Passage Bolts, And End Plate Assembly
  • 8. Remove Sandwich Plate, Fuel Pump Blades, And Transfer Pump Liner
  • 9. Loosen And Remove Outer Rotor Head Assembly And Sealing Ring
  • 10. Remove Access Cover And Fuel Connection
  • B. Disassemble Continued
  • B. Disassemble Continued
  • 12. Remove Screw, Cam Ring, And Retaining Ring.
  • E. Remove Socket Head Cap Screw
  • E. Lower Governor Weight Cage
  • 15. Remove Sealing Ring
  • 1. Inspect Fuel Injection Pump Housing For Corrosion And Scoring.
  • 4. Inspect Roller Shoes And Rollers For Free Rotation And Damage
  • 1. Install Sealing Ring
  • 3. Install Drive Hub And Governor Weight Cage Into Fuel Injection Pump
  • E. Assemble Continued
  • 4. Install Retaining Ring, Cam Ring, And Screw Into Fuel Injection Pump
  • 5. Install Fuel Connection And Access Cover
  • D. Position Pump Plate Assembly
  • 7. Install Nozzle Testing Unit Onto Rotor Head Assembly And Measure Roller-To-Roller Dimension
  • 8. Install Piston, Spring, Shim, Spring Cap, And Hex Head Cap Screw Into Auto Advance Housing
  • 9. Install Gasket, Auto Advance Piston Housing Assembly, And Cap Nut To Fuel Injection Pump And Assemble Sealing Rings And Ball To Fluid Passage Bolt.
  • 10. Install Rotor Head Assembly To Fuel Injection Pump
  • N. Turn Fuel Injection Pump Over
  • 11. Install Transfer Pump Liner, Fuel Pump Blades, And Sandwich Plate
  • 13. Install End Plate Assembly, Banjo Bolts, And Fluid Passage Bolts Onto Fuel Injection Pump
  • 14. Assemble And Install Spring Link, Metering Valve, And Governor Arm Assembly
  • 15. Install Shutoff Bar, Keep Plate, And Shouldered Studs
  • 17. Install Spring, Spring Holder, And Spring, And Attach Spring To Throttle Shaft
  • 19. Install Hex Head Cap Screws, Cap Nuts, Sleeve, Wire Rope, Springs, And Levers Onto Fuel Injection Pump
  • F. Test
  • Test Operation
  • F. Test - Continued
  • G. Install
  • 2. Install Fuel Injection Pump Onto Engine
  • 3. Install Tachometer Generator Onto Engine
  • Follow-On-Tasks
  • A. Disassemble
  • 2. Remove Filter Cover, Preformed Packing, Filter Screen, And Valves From Cover
  • 1. Clean All Parts In Warm, Soapy Water. Allow Parts To Soak For Several Minutes
  • 2. Inspect Body (4) For Warped Flanges, Worn Rocker Arm, And Worn Or Broken Rocker Arm Spring
  • 2. Install Valves, Preformed Packing, Filter Screen, And Filter Cover On Cover.
  • 3. Assemble Fuel Lift Pump Cover To Body.
  • 2.21 Repair Turbosupercharger.
  • 2. Clamp Compressor Housing In A Vise And Remove Compressor Wheel And Plate
  • 3. Remove Impeller Shaft, Bearings, And Shroud From Compressor Housing
  • B. Clean
  • C. Inspect
  • 3. Inspect Plate For Chafing And Scoring
  • D. Assemble.
  • 2. Clamp Compressor Housing In A Bench Vise And Install Compressor Wheel And Plate
  • 3. Install Wheel Housing And Impeller Housing Onto Compressor Housing
  • 2.22. Replace/Repair Fuel Tank
  • 2. Disconnect Fuel Hoses From Fuel Tank
  • 5. Remove Fuel Tank
  • C. Unscrew Fuel Tank Cap
  • 7. Remove Fuel Level Transmitter
  • B. Clean
  • 2. Clean Fastener Threads
  • C. Adjust
  • D. Install
  • 2. Install Fuel Filler Assembly
  • 4. Install Fuel Tank
  • G. Apply Thread Locking Compound
  • 5. Install Fuel/Water Separator.
  • 7. Install Fuel Hoses
  • 2.23 Repair Water Pump
  • B. Clean
  • C. Assemble
  • 3. Install Seal Into Bearing Body
  • 4. Install Impeller Onto Assembled Shaft
  • 2.24 Repair Alternator
  • A. Disassemble
  • 6. Test Rectifier Diodes At Winding Ends Per Tm 9-2920-247-34 Using A Digital Multimeter
  • 9. Remove Rectifier And Electrical Cover From Collector Ring End Shield
  • 1. Wipe Drive End Bell (35), Rotor (29), Collector Ring End Shield (12), And Electrical Cover (28) With A Cleaning Cloth Dampened With Cleaning Solvent
  • C. Inspect
  • 5. Inspect Collector Rings And Rotor For Wear And Out-Of-Roundness
  • D. Repair
  • 4. Install Rectifer Into Collector Ring End Shield
  • 5. Install Stator Into Collector Ring End Shield
  • 7. Install Transistor And Carbon Brush Assembly.
  • 2.25 Repair Starter Assembly
  • A. Disassemble
  • G. Remove Frame And Brush Assembly
  • 2. Remove Brushes, Brush Springs, And Brush Holder Assembly From Frame And Brush Assembly
  • 3. Remove Armature Support, Shift Lever, And Drive Shaft From Drive Housing
  • 4. Remove Sleeve Bushing, Stop Ring, Bendix, And Drive Support From Drive Shaft And Remove Burrs From Drive Shaft
  • B. Clean
  • 5. Inspect Bearings On Drive Shaft And Armature
  • 1. Remove And Replace Sleeve Bearing In Drive Housing
  • 2. Remove And Replace Bearing On Drive Shaft
  • 3. Remove And Replace Bearings On Armature
  • E. Assemble.
  • 2. Assemble Armature Support, Shift Lever, And Drive Shaft Into Drive Housing
  • 3. Assemble Brushes And Brush Springs. Install Brush Holder Assembly Into Frame/Field Assembly
  • 4. Install Solenoid Into Drive Housing
  • 5. Install O-Ring, Frame And Brush Assembly, And Commutator End Frame Onto Drive Housing And Armature Assembly. Install Motor Lead Onto Solenoid
  • F. Test
  • 2.26 Repair Control Handle
  • 3. Remove Retaining Plate And Boot From Control Handle
  • 4. Wipe Threads On Handle Dry With A Clean, Lint-Free Cloth
  • 1. Install Boot And Retaining Plate Onto Control Handle
  • 3. Install Case Gasket, Case, And Strain Relief Connector Onto Control Handle
  • Section Vii. Transmission System Maintenance
  • 1. Remove Electrical And Hydraulic Connections
  • 2.27 Replace/Repair High Speed Shift Valve
  • 2. Remove Solenoid Assembly
  • 3. Remove Electrical Housing And Valve Body
  • 4. Remove And Disassemble Subplate
  • C. Clean
  • D. Inspect
  • 2. Inspect Spool
  • 1. Assemble Valve Body
  • 2. Assemble Subplate And Install Onto Mounting Brack
  • 3. Install Valve Body And Electrical Housing Onto Subplate
  • 4. Install Solenoid Assembly
  • 5. Install Electrical Cable
  • 2. Install Electrical And Hydraulic Connections
  • 2.28 Replace/Repair Brake Valve.
  • B. Repair
  • 2. Clean Valve Body And Rotary Valve
  • 3. Clean Threaded Components.
  • C. Lubricate Interior Of Valve Body
  • C. Install
  • 2.29 Replace/Repair Pump Drive Gearbox
  • A. Remove
  • 3. Remove Pump Drive Gearbox From Engine.
  • E. Install Hex Head Screw Caps
  • 4. Remove Pump Drive Gearbox From Engine Compartment
  • B. Disassemble
  • C. Clean
  • D. Inspect
  • F. Assemble.
  • K. Align Matchmarks And Install Cover Plates
  • G. Install
  • 2. Install Pump Drive Gearbox Onto Engine
  • I. Coat Gear Teeth Of Adapter Gear Sleeve
  • O. Apply Hydraulic Fitting Sealant Onto Exposed Threads Of Elbow
  • Follow-On-Tasks
  • 2.30 Replace/Repair Propulsion Pump
  • A. Remove
  • F. Tag And Disconnect Hydraulic Charge Filter Hoses
  • 2. Disconnect Electrical Connections And Hydraulic Hoses From Left Propulsion Pump
  • 3. Remove Propulsion Pump
  • 2. Remove Hydraulic Fittings From Right Propulsion Pump
  • 3. Remove Plain Seal
  • 5. Remove Scr Valves
  • 7. Remove Cover Plate, A-Flange Adapter And Gerotor Set
  • 8. Remove Remote Filter Adapter
  • 10. Remove Front Cover, Gasket, And Swash Plate
  • 11. Remove Pump Shaft, Bearing, And Sleeve Bearings
  • 13. Remove Pump Pistons, Slipper Retainer, And Retainer Guide
  • 15. Remove Servo Piston
  • 16. Remove Servo Spring From Servo Piston
  • C. Clean.
  • 2. Clean Cap Screws
  • D. Inspect
  • 5. Inspect Sealing Surfaces In End Cap Assembly Housing
  • 7. Inspect Retainer Guide And Slipper Retainer For Scoring
  • E. Assemble
  • 3. Install Servo Spring Into Servo Piston
  • 4. Install Bearing Rings, Preformed Packings, And Piston Ring On Servo Piston
  • 5. Install Servo Piston
  • 6. Install Valve Plate
  • 8. Install Cylinder Block Assembly
  • 9. Install Bearing, Pump Shaft, And Sleeve Bearing
  • 10. Install Swash Plate, Gasket, And Front Cover
  • 11. Install Electronic Displacement Control
  • 13. Install Gerotor Set, A-Flange Adapter, And Cover Plate Onto End Cap Assembly Housing
  • 14. Install Spring Seat Into End Cap Assembly Housing
  • 16. Install Safety Relief Valve Into End Cap Assembly Housing
  • 18. Install Hydraulic Fittings Onto Right Propulsion Pump
  • 19. Install Hydraulic Fiti’ings Onto Left Propulsion Pump
  • F. Install
  • 2. Connect Hydraulic Hoses And Electrical Connections To Ight Propulsion Pump
  • G. Apply Electrical Insulating Varnish
  • 3. Connect Hydraulic Hoses And Electrical Connections O Left Propulsion Pump
  • G. Adjust
  • D. Remove Plugs
  • G. Adjust - Continued
  • G. Adjust - Continued
  • 3. Set Electronic Displacement Control Position To Neutral
  • 4. Remove Cribbing And Lower Paving Machine
  • 2.31 Replace Pump Pilot Control Valve
  • 2. Remove Preformed Packings From Pump Pilot Control Valve
  • B. Install
  • 3. Check Paving Machine Control Handle Tracking
  • 2.32 Replace/Repair Propulsion Motor
  • A. Remove
  • 2. Remove Propulsion Motor
  • B. Disassemble
  • 2. Remove Valve Assembly From Hydraulic Assembly Housing
  • 3. Remove Pressure Valve Assembly From Hydraulic Assembly Housing
  • 5. Remove Piston And Displacement Rod From Port Plate Housing
  • 6. Remove Cylinder Block From Mechanical Drive Housing
  • 7. Remove Motor Cover And Shaft Assembly From Mechanical Drive Housing
  • C. Clean
  • 2. Clean Fasteners, Set Screws And Parts Treated With Thread Compound In Thread Locking Compound Solvent.
  • D. Inspect
  • 3. Inspect Valve Assembly Components For Nicks, Damage, And Signs Of Contamination
  • E. Assemble.
  • 2. Measure Depth Of Port Plate In Relation To Port Plate Housing Flange
  • D. Install Cylinder Block
  • 4. Install Spring, Ring Spacer, And Retaining Ring Into Cylinder Block
  • 5. Install Piston And Displacement Rod Into Port Plate Housing
  • I. Install Tube
  • 6. Install Port Plate Housing Onto Mechanical Drive Housing
  • 7. Install Pressure Valve Assembly Into Hydraulic Assembly Housing.
  • 8. Install Valve Assembly Into Hydraulic Assembly Housing.
  • J. Install Set Screws
  • 9. Install Hydraulic Assembly Housing Onto Mechanical Drive Housing
  • F. Adjust
  • G. Install
  • 2. Install Propulsion Motor
  • 3. Connect Hydraulic Tubes
  • 2.33 Replace/Repair Speed Reduction Gearbox.
  • A. Remove.
  • 2. Remove Speed Reduction Gearbox
  • 3. Remove Flange And Ring Seal
  • B. Disassemble
  • I. Direct Compressed Air Into Straight Adapter
  • 2. Remove Speed Reduction Gearbox Components
  • D. Remove Plugs
  • J. Remove Plugs
  • 3. Disassemble Angle Drive Unit
  • C. Clean
  • 2. Clean Threaded Fasteners
  • D. Inspect - Continued
  • E. Assemble
  • 2. Assemble Speed Reduction Gearbox Components
  • E. Apply Light Coating Of Petrolatum
  • O. Align Matchmarks On Internal Gear  
  • T. Stand Speed Reduction Gearbox
  • 3. Assemble Brake Components
  • H. Lubricate O-Ring
  • Q. Lubricate O-Ring With Petrolatum
  • F. Install
  • 2. Install Flange Components.
  • 3. Install Speed Reduction Gearbox
  • 4. Install Hydraulic Line
  • Section Viii. Track Assembly Maintenance
  • A. Remove
  • 3. Lift Track Frame Clear Of Main Frame
  • B. Replace.
  • 3. Install Track Frame On Main Frame
  • F. Tighten Hex Head Cap Screws
  • 2.35 Replace Track Rollers
  • A. Inspect
  • B. Remove
  • 2. Clean Mounting Hardware.
  • 2. Install Lower Track Roller
  • 2.36 Replace/Repair Track Idler Roller Assembly
  • A. Disassemble
  • 2. Disassemble Track Idler Roller Assembly
  • B. Clean
  • C. Inspect.
  • D. Assemble
  • I. Use A Marker To Indicate Location Of Set Screw
  • 2. Install Track Idler Roller Assembly.
  • 2.37. Replace Track Tensionoing Cylinder
  • 2. Remove Track Tensioning Cylinder
  • 3. Remove Elbow And Pipe Bushing From Cylinder
  • 2. Install Track Tensioning Cylinder
  • 2.39. Replace/Repair Track Tensioning Relief Valve And Unload
  • A. Remove
  • B. Disassemble
  • B. Disassemble - Continued
  • 2. Disassemble Track Tensioning Unloading Relief Valve
  • G. Remove Plug And Preformed Packing From Valve Body
  • C. Clean
  • 2. Clean Bolts Treated With Thread Locking Compound
  • D. Inspect
  • 2. Inspect Track Tensioning Unloading Valve
  • E. Assemble
  • I. Install Valve Slide
  • M. Install Valve Disk
  • 2. Assemble Track Tensioning Relief Valve
  • F. Install
  • 2. Install Track Tensioning Relief Valve And Track Tensioning Unloading Valve
  • 3. Connect Hydraulic Lines And Hoses
  • 2.39. Repair Track Tensioning Cylinder
  • A. Disassemble
  • 2. Disassemble Piston Rod Assembly
  • C. Inspect
  • 2. Inspect Piston Rod.
  • 4. Inspect Split Piston Halves
  • D. Assemble
  • 2. Reassemble Piston Rod Assembly
  • B. Apply Hydraulic Oil To Threads On Cylinder Head
  • 2.40 Replace/Repair Track Drive Hub
  • A. Remove.
  • F. Remove Uppermost Hex Head Cap Screw
  • 3. Remove Hub Drive Shaft
  • 4. Remove Remaining Bearing Components, Flat Washer, Plain Seal, Nonmetallic Seal, Drive Sprocket Gear Mounting Studs, And Lubrication Fitting
  • D. Install
  • 3. Install Tapered Roller Bearing
  • E. Set Up Hub Drive Shaft
  • 5. Install Plain Seal, Flat Washer, And Bearing Self-Locking Nut
  • 6. Install Track Drive Hub In Paving Machine
  • F. Align Matchmarks On Main Frame And Track Drive Hub
  • 7. Install Drive Sprocket Gear
  • 2.41 Replace Track Chain Assembly
  • A. Remove.
  • D. Use Cleaning Solvent And Cleaning Cloth To Clean All Dust, Dirt, And Oil Or Grease Residue
  • Track Chain Assembly Weight  
  • 2. Remove Track Chain Assembly
  • D. Stop Track Drive When Leading End Of Track Chain Assembly
  • 2. Connect Track Tensioning Cylinder Hose
  • Section Ix. Hydraulic Systems Maintenance
  • A. Remove
  • 3. Remove Auxiliary Pump From Engine Compartment
  • 1. Disassemble Front Plate Assembly, Pump Bodies, Adapter Plate Assembly, And Backplate Assembly
  • 2. Remove Diaphragm, Backup Gasket, Protector Gasket, Diaphragm Seal, Springs, And Steel Balls From Front Plate Assembly
  • 3. Remove Drive Gear Assembly, Idler Gear Assembly, Keys, Shafts, And Preformed Packing From Adapter Plate Assembly
  • 5. Remove Backplate Assembly Plugs, Springs, And Valves
  • C. Clean
  • 1. Inspect Gears For Burrs, Scoring, And Wear.
  • 4. Inspect Front Plate, Backplate, And Adapter Plate Assembly Bearings For Wear
  • 1. Install Backplate Assembly Valves, Springs, And Plugs
  • 2. Install Diaphragm Seal, Protector Gasket, Backup Gasket, Diaphragm, Dowel Pins, And Rear Pump Body
  • 3. Install Preformed Packings, Key, And Gear Assemblies
  • 4. Install Diaphragm Seal, Protector Gasket, Backup Gasket, Diaphragm, Steel Balls, And Springs Into Front Plate Assembly
  • 5. Assemble Backplate Assembly, Adapter Plate Assembly, And Front Plate Assembly
  • F. Install
  • 2. Install Auxiliary Pump On Paving Machine
  • Follow-On-Tasks
  • 2.43 Replace/Repair Auxiliary Vibration Pump.
  • A. Remove
  • 2. Remove Vibration Relief Valve And Adapters
  • 1. Disassemble Auxiliary Vibration Pump And Adapter Body
  • 2. Disassemble Auxiliary Vibration Pump
  • G. Lay Pump Housing
  • Use Caution When Removing Shaft Seal
  • C. Clean
  • 2. Clean Screw Threads
  • D. Inspect
  • 3. Inspect Bearing Units
  • E. Assemble.
  • 2. Install Shaft Seal
  • 3. Assemble Auxiliary Vibration Pump
  • E. Seat Rounded Sides Of Seals
  • J. Dry Clean Surfaces With Clean, Dry, Lint-Free Cloths
  • S. Pour A Small Amount Of Clean Hydraulic Oil
  • 4. Assemble Auxiliary Vibration Pump And Adapter Body
  • 2. Install Vibration Relief Valve And Adapters
  • 3. Install Hydraulic Hoses
  • 2.44 Repair Stack Valve And Stack Valve Wiring Harness
  • Stack Valve Electrical Coil Wiring
  • 1. Remove Stack Valve Wiring Harnesses
  • 3. Remove Valve Spool
  • 5. Remove Check Valve
  • 6. Remove Preformed Packings And Packing Retainers
  • 7. Remove Manifold Interface O-Rings
  • 9. Remove Valve Electrical Coil Connector From Stack Valve Wiring Harness
  • 2. Dry Cleaned Components With Clean, Dry, Lint-Free Cloths
  • C. Install
  • E. Pull Harness Wiring From Packing Port
  • 2. Install Hose Or Tube Adapters
  • 3. Install Manifold Interface O-Rings
  • 4. Install Preformed Packings And Packing Retainers
  • 5. Install Check Valve
  • 7. Install Valve Spool
  • 9. Install Stack Valve Wiring Harnesses
  • 2.45 Repair Auger/Conveyor Control Valve
  • 1. Remove Elbow, Swivel Elbow, Straight Adapters, Threaded End Rods, And Angle Brackets From Auger/Conveyor Control Valve
  • 3. Remove Electrical Coils, Sleeves, Tubes, And Spool From Valve Body
  • 1. Rinse All Metal Parts In Cleaning Solvent
  • C. Inspect
  • 2. Inspect Spool For Damage And Wear
  • 4. Inspect Relief Valve Assembly Body.
  • 1. Assemble Relief Valve Assembly
  • 2. Install Spool, Tubes, Sleeves, And Electrical Coils Into Valve Body.
  • 3. Install Relief Valve Assembly And Threaded End Rods Onto Auger/ Conveyor Control Valve
  • 4. Install Straight Adapters, Swivel Elbow, And Elbow Onto Auger/ Conveyor Control Valve
  • 2.46 Repair Tow Point Control Valve
  • A. Disassemble
  • 3. Remove Threaded End Rods, Outlet And Inlet Manifolds, And Lock Valve From Tow Point Control Valve
  • 5. Remove Valve Cap Nut, Adjustment Screw, Spring, And Poppet From Inlet Manifold
  • B. Clean
  • C. Inspect
  • 2. Inspect Inlet Manifold And Outlet Manifold For Damage And Wear
  • 3. Inspect Spool For Scoring And Wear
  • D. Assemble.
  • 2. Install Spool, Tube Assemblies, And Electrical Coils Onto Valve Body
  • 3. Install Lock Valve, Inlet And Outlet Manifolds, And Threaded End Rods Onto Tow Point Control Valve
  • 4. Install Mounting Brackets And Threaded End Rods On Tow Point Control Valve
  • 2.47 Replace/Repair Screed Vibration Solenoid Valve
  • 2. Remove Fittings From Screed Vibration Solenoid Valve.
  • 2. Clean Valve Body And Valve Cartridge
  • 3. Assemble Screed Vibration Solenoid Valve
  • C. Install
  • 2. Install Screed Vibration Solenoid Valve Onto Return Manifold
  • 2.48 Repair Auger/Conveyor Speed Control Valve
  • A. Disassemble
  • 3. Disassemble Cross
  • 4. Disassemble Auger/Conveyor Speed Control Valve
  • B. Clean
  • 2. Clean Hex Head Cap Screws And Set Screws
  • 2. Inspect Spool For Damage And Wear
  • D. Assemble
  • D. Install Spring
  • M. Install And Tighten Set Screw
  • 2. Assemble Cross
  • G. Install Swivel Elbow  
  • 3. Install Assembled Cross And Mounting Bracket
  • G. Align Mounting Bracket  
  • 2.49 Repair Auger/Conveyor, Valve And Cylinder, And Tow Point Flow Dividers
  • 2. Remove Mounting Brackets From Flow Divider
  • 3. Remove End Plates, Cases, And Dowel Pins From Flow Divider
  • 4. Remove Retaining Rings, Gears, Dowel Keys, And Shafts From Spacer Plate
  • B. Clean
  • 2. Clean Fastener Threads
  • 3. Inspect Shaft For Scoring And Wear
  • D. Assemble
  • 2. Install Dowel Pins, Cases, And End Plates Onto Flow Divider
  • 3. Install Mounting Brackets On Flow Divider
  • 5. Install Hydraulic Fittings On Flow Divider
  • Follow-On-Task
  • 2.50 Repair Tow Point Flow Control Valve
  • 2. Disassemble Tow Point Flow Control Valve
  • 3. Disassemble Flow Adjustment Assembly
  • B. Clean
  • C. Inspect.
  • D. Assemble
  • 3. Assemble Tow Point Flow Control Valve
  • 4. Install Fittings Onto Tow Point Flow Control Valve
  • 2.51 Adjust Unloading And Relief Valves
  • 2. Check On-Machine Unloading And Relief Valves
  • 1. Adjust Stack Relief Valve
  • 3. Adjust Track Tensioning Unloading Valve
  • 5. Adjust Auger/Conveyor Relief Valves
  • 6. Adjust Tow Point Control Valves
  • 2.52 Repair Tow Point Cylinder
  • 2. Remove Clevis, Cylinder Head, And Piston
  • B. Clean
  • C. Inspect
  • 2. Inspect Piston Rod
  • 4. Inspect Cylinder Head
  • D. Assemble.
  • 2. Install Preformed Packings And Seals
  • 3. Assemble Piston Components
  • 4. Assemble Piston And Cylinder
  • 2.53 Replace/Repair Hydraulic Reservoir Components
  • A. Remove
  • 2. Remove Hydraulic Hoses
  • 3. Disconnect Test Manifold
  • 5. Remove Hydraulic Reservoir Filler Opening Cap Assembly
  • B. Use Crowbar To Lift Rear Of Hydraulic Reservoir
  • F. Attach Sling Straps
  • 7. Remove Elbows And Plugs
  • 8. Remove Hydraulic Reservoir Cover And Gasket
  • B. Clean
  • 2. Clean Fasteners
  • C. Install
  • 2. Install Drain Hose
  • 4. Nstall Gasket And Hydraulic Reservoir Cover
  • 5. Install Plugs And Elbows
  • 6. Install Hydraulic Reservoir
  • H. Apply Thread Locking Compound To Threads
  • 7. Install Hydraulic Reservoir Filler Opening Cap Assembly
  • 8. Install Engine Oil Cooler, Filter Differential Pressure Transmit’-I’er, And Attached Hoses
  • 9. Install Test Manifold
  • 11. Install Bulkhead Partition
  • 2.54 Replace Hydraulic Hoses, Tubes, And Fittings
  • A. Remove
  • 2. Remove Hoses, Tubes, And Fillings
  • B. Use A Cleaning Cloth And Cleaning Solvent To Remove Grease And Other Buildup  
  • E. Slowly Loosen Tube Coupling Nut
  • B. Clean
  • 1. Install Straight Fittings
  • 2. Install O-Ring Boss (Orb) Fittings
  • 3. Install Tapered Pipe Thread Fittings
  • C. Apply Hydraulic Fitting Sealant
  • F. Install Anti-Chafing Pads
  • A. Use Compressed Air  
  • D. Tag, Disconnect, And Plug Hoses
  • Hydraulic Oil Under Pressure Can Penetrate Skin Or Damage Eyes.
  • D. Shut Off Engine And Remove Key From Ignition Switch
  • 2.54. Repair Hydraulic Hoses, Tubes, And Fittings - Continued
  • 1. General Removal Instructions
  • Tow Point Flow Control Valve
  • 2. Remove Dca Housing
  • 3. Remove Return Manifold
  • F. Tag And Disconnect Tube
  • N. Disconnect Screed Vibration Solenoid Valve
  • 4. Remove Tow Point Mount Plate
  • D. Tag And Disconnect Hoses
  • F. Cut And Remove Tie Wraps
  • 5. Remove Tubes And Hoses From Right Auger/Conveyor Speed Control Valve
  • 6. Remove Tubes And Hoses From Left Auger/Conveyor Speed Control Valve
  • . Remove Auger/Conveyor Speed Control Valve.
  • 8. Remove Tow Point Flow Divider And Tow Point Flow Control Valve
  • E. Remove Hex Nuts
  • 9. Remove Tow Point Control Valves
  • E. Remove Hex Nuts
  • 10. Remove Auger/Conveyor Control Valves
  • F. Remove Bolts  
  • 11. Remove Valve And Cylinder Flow Divider
  • F. Tag And Disconnect Swivel Elbow
  • 12. Remove Auger/Conveyor Flow Divider
  • D. Tag And Disconnect Tubes
  • 13. Remove Stack Valve
  • H. Tag And Disconnect Hoses
  • I. Tag And Disconnect Hoses
  • B. Clean
  • 2. Clean Valve Panel Area Where Control Valve Or Flow Divider Has Been Removed
  • 1. Install Stack Valve
  • H. Apply Hydraulic Fitting Sealant
  • K. Connect Hoses
  • Q. Apply Electrical Insulating Compound
  • 2. Install Auger/Conveyor Flow Divider
  • F. Connect Tubes
  • D. Install Lockwashers
  • E. Apply Hydraulic Fitting Sealant To The Exposed Threads Of Tube Reducer
  • A. Place Auger/Conveyor Control Valve
  • B. Install Lockwashers
  • E. Apply Hydraulic Fitting Sealant
  • H. Apply Electrical Insulating Compound To Male Ends Of Auger/Conveyor Control Valve Electrical Connectors
  • 5. Install Tow Point Control Valves
  • D. Connect Rear Tow Point Control Valve
  • 6. Install Tow Point Flow Divider
  • G. Connect Swivel Tee
  • 7. Install Auger/Conveyor Speed Control Valve
  • 8. Install Tubes And Hoses Onto Right Auger/Conveyor Speed Control Valve
  • 9. Install Tubes And Hoses Onto Left Auger/Conveyor Speed Control Valve
  • 10. Install Tow Point Mount Plate
  • E. Apply Hydraulic Fitting Sealant To Exposed Threads Of Elbows
  • I. Apply Hydraulic Fitting Sealant To Exposed Threads Of Swivel Tee
  • K. Apply Electrical Insulating Compound To Male Ends Of Front Tow Point Control Valve Electrical Connector
  • 11. Install Return Manifold On Engine Cowling
  • H. Apply Hydraulic Fitting Sealant To Exposed Threads On Elbows
  • I. Apply Hydraulic Fitting Sealant To Exposed Threads On Elbows
  • R. Apply Electrical Insulating Compound To Male Fittings Of Electrical Connectors
  • 12. Install Dca Housing And Housing Bracket On Engine Cowling
  • 2.56 Replace Screed Vibration Control Valve
  • 2. Remove Tees And Elbows From Screed Vibration Control Valve
  • 1. Install Tees And Elbows Onto Screed Vibration Control Valve
  • 2. Install Screed Vibration Control Valve
  • 2.57 Replace Screed Travel Lock Valve
  • A. Remove
  • 2. Remove Screed Travel Lock Valve
  • . Connect Hydraulic Hoses
  • Section X. Paving Machine Components Maintenance
  • 2.58 Replace/Repair Extension Screed Height Adjustment
  • A. Remove
  • 4. Remove Lift Jack Assembly
  • 5. Remove Vertical Adjustment Block Assembly
  • 6. Disassemble Vertical Adjustment Block Assembly.
  • B. Clean
  • C. Install
  • 2. Install Vertical Adjustment Block Assembly
  • 3. Install Lift Jack Assembly
  • 4. Install Lift Jack Assembly Connecting Shaft And Height Adjustment Knobs
  • M. Slide Inner Height Adjustment Knob
  • 5. Install Mounting Bracket And Catch Plate
  • D. Adjust
  • A. Remove
  • 2. Remove Scraper
  • 3. Support Hopper Wing With Overhead Hoist
  • 4. Remove Headless Straight Rod
  • 5. Remove Hopper Wing.
  • 2. Install Headless Straight Rod
  • 3. Install Scraper
  • 4. Install Flashing, Conveyor Access Door, And Extension Bracket
  • K. Install Flat Washers
  • 2.60 Repair Hopper Lift Cylinder
  • 1. Remove Retaining Ring
  • B. Clamp Head End Of Piston Rod
  • B. Clean
  • C. Inspect
  • 2. Inspect Piston Rod
  • 4. Inspect Piston
  • D. Repair
  • 2. Install Spherical Bearing
  • E. Assemble.
  • 2. Assemble Piston Components.
  • 3. Assemble Piston Rod And Cylinder Tube
  • G. Insert Retaining Ring
  • 2.61 Replace Conveyor Chain Assembly
  • 2. Remove Conveyor Access Door
  • 4. Remove Conveyor Drag Plate Guard
  • 6. Reduce Chain Tension
  • 8. Remove Conveyor Chain Assembly
  • B. Clean
  • C. Inspect
  • 4. Inspect Conveyor Drive Shaft, Bearing Units, And Sprocket Wheels
  • 2. Install Inner And Outer Chain Guide Bars
  • 3. Install Conveyor Chain Assembly Onto Sprocket Wheel And Conveyor Drive Shaft.
  • 4. Position Offset Links For Recon- Necting Conveyor Chain Assembly
  • 5. Connect Loose End Of Conveyor Chain Assembly At Offset Links
  • 6. Align Conveyor Chain Assembly
  • G. Clean Threads Of Set Screws
  • 7. Replace Conveyor Chain Guards
  • 9. Replace Conveyor Access Door
  • 10. Install Center Flashing
  • 2.62 Replace Conveyor Drag Plates And Engine Insulation Pan.
  • A. Remove
  • 2. Remove Chain Plate Lid
  • 4. Remove Engine Insulation Pan And Insulation
  • B. Clean
  • 1. Install Insulation And Engine Insulation Pan.
  • 2. Replace Rear Conveyor Drag Plate
  • 3. Replace Chain Plate Lid.
  • 4. Replace Front Conveyor Drag Plate
  • 2.63 Replace And Adjust Auger/Conveyor Drive Chain.
  • A. Remove
  • 2. Remove Center Cover
  • 4. Remove Top Chain Cover Plate From Auger/Conveyor Drive Chain Housing
  • 6. Loosen Auger/Conveyor Drive Chain
  • B. Clean
  • 1. Replace Auger/Conveyor Drive Chain
  • D. Adjust
  • E. Install.
  • 3. Install Center Cover
  • 4. Install Bottom Cover Plate And Rear Cover Plate On Auger/Conveyor Drive Chain Housing
  • 2.64 Replace/Repair Conveyor Drive Shaft, Bearing Units, And Sprocket Wheels
  • A. Remove
  • 2. Clean Assembled Conveyor Drive Shaft
  • 3. Disassemble Conveyor Drive Shaft Assembly
  • B. Clean
  • 2. Clean Main Frame At Bearing Plate Mounting Surfaces And Drive Shaft Through-Ways
  • 2. Inspect Sprocket Wheel Teeth And Keyway
  • 2. Assemble Drive Shaft.
  • 3. Install Drive Shaft As An Assembly
  • 4. Level Drive Shaft
  • 5. Align Drive Shaft And Sprocket Wheels
  • 6. Align Sprocket Wheel
  • 2.65 Replace/Repair Conveyor Roller And Bearing Units
  • A. Remove.
  • 3. Remove Tension Bolts And Bearing Support Plates
  • 1. Clean All Metal Parts
  • 2. Clean Bearing Support Plate Mounting Surfaces
  • 1. Inspect Conveyor Roller
  • 2. Install Bearing Support Plates And Tension Bolts
  • 3. Install Conveyor Roller And Bearing Units As An Assembly
  • 2.66 Replace Extension Screed Frame.
  • A. Remove.
  • 2. Remove Screed Steps, And Handrail
  • D. Remove Hex Head Cap Screws
  • J. Remove Hex Nuts
  • 3. Remove Screed Cover Plates
  • 5. Remove Extension Screed Blower
  • 6. Remove Extension Screed Burner Chamber Assembly
  • F. Slide Shield
  • 7. Remove Extension Screed Plate
  • 9. Disconnect Extension Screed
  • 10. Remove Extension Screed
  • 11. Remove Extension Screed Hydraulic Lines And Fittings
  • 12. Remove Extension Screed Base
  • 13. Remove Height Adjust Components
  • B. Clean
  • C. Inspect
  • 2. Inspect Extension Screed Base
  • D. Install
  • D. Install
  • I. Position Catch Plate Mounting Bracket
  • 5. Couple Extension Screed Frame To Extension Screed Base
  • 6. Install Extension Screed Hydraulic Lines And Fittings
  • D. Install
  • 7. Install Extension Screed
  • G. Apply Hydraulic Fitting Sealant To Threads Of Elbows
  • 1. Route Screed Harness
  • 9. Install Burner Chamber Assembly
  • J. Install And Tighten Screed Burner Fuel Hose
  • 10. Install Blower
  • 11. Install Screed Steps
  • D. Install - Continued
  • H. Remove Second Hex Head Cap Screw
  • Q. Remove Second Hex Nut
  • 12. Install Screed Handrail
  • 13. Install Screed Steps
  • 14. Install Screed Cover Plates
  • 2.67 Replace Main Screed Frame
  • 2. Remove Main Screed Vibrator Components From Main Screed
  • 3. Remove Burner Chamber Assembly From Main Screed
  • H. Remove Flexible Pipe
  • 5. Remove Screed Arm
  • C. Tag And Disconnect Left Hand Extension Screed Vibration Hoses
  • 7. Remove Hydraulic Hoses, Tubes, And Fittings From Right Hand Main Screed Frame
  • 8. Disconnect And Lay Aside Screed Burner Manifold
  • 9. Disconnect And Lay Aside Crown Adjustment Assembly
  • 10. Remove Blower Assembly.
  • 13. Separate Main Screed Frames
  • B. Clean
  • 2. Clean All Fasteners Treated With Thread Locking Compound
  • C. Inspect
  • 2. Inspect Main Screed Plate
  • D. Install
  • 2. Install Side Plate
  • 4. Install Blower Assembly.
  • 5. Connect Crown Adjustment Assembly
  • 6. Connect Screed Burner Manifold
  • 7. Install Fittings, Tubes And Hydraulic Hoses Onto Right Hand Main Screed Frame
  • 8. Install Fittings, Tubes, And Hydraulic Hoses Onto Left Hand Main Screed Frame
  • G. Connect Left Hand Extension Screed Vibration Hoses
  • 9. Install Screed Arm
  • 11. Install Burner Chamber Assembly
  • K. Apply Hydraulic Fitting Sealant To Threads Of Elbow
  • 12. Install Main Screed Vibrator Components
  • K. Apply Anti-Seize Compound
  • 2.68 Replace Auger Bearing Units, Shaft, And Sprocket Wheel.
  • A. Remove
  • 2. Remove Shaft And Bearing Units From The Paving Machine
  • 4. Remove Bearing Unit From Bearing Mount
  • 2. Clean Fasteners Treated With Thread Locking Compound
  • C. Inspect
  • D. Install
  • 3. Install Shaft
  • 4. Install Bearing Mount On Main Frame
  • Follow-On-Tasks
  • 2.69 Replace/Repair Auger/Conveyor Motor And Drive Sprocket Wheel
  • A. Remove
  • 3. Remove Inboard Battery
  • 4. Disconnect Screed Burner Fuel Line, Screed Hydraulic Hoses, And Tubes At Tractor Rear Bulkhead
  • A. Remove - Continued
  • G. Wipe Up Any Spilled Fuel Or Hydraulic Oil
  • 5. Disconnect Screed Extension Cylinder Extend And Retract Hydraulic Hoses And Screed Vibration Control Valve Tubes At Tractor Rear Bulkhead.
  • 6. Disconnect Screed Extension Cylinder Return Line Tube From Return Manifold And Set Aside. Disconnect Screed Vibration Solenoid Valve Tube 5 From Screed Vibration Solenoid Valve And Set Aside
  • 7. Remove Rear Cover Plate From Auger/ Conveyor Drive Chain Housing
  • 8. Disconnect Hydraulic Hoses From Auger/Conveyor Motor In And Out Ports.
  • 10. Remove Top Chain Cover Plate, Lift Auger/Conveyor Drive Chain Off Sprocket Wheel, And Remove Elbows
  • 1. Remove Drive Sprocket Wheel And Motor Mount From Auger/Conveyor Motor
  • 3. Remove Check Valve, Separate Valve Housing From Auger/Conveyor Motor, Counterbalance Weight Assembly, Compression Springs, And Valve
  • B. Disassemble - Continued
  • 4. Remove Valve Plate, Valve Drive Shaft, Gear Set, And Multiple Gear Shaft From Bearing Housing And Shaft Assembly
  • 2.69 Replace/Repair Auger/Conveyor Motor And Drive Sprocket Wheel - Continued
  • C. Clean
  • 2. Clean All Fasteners With Thread Locking Compound Solvent
  • 2. Inspect Valve Housing
  • 4. Inspect Gear Set
  • 1. Lubricate And Install Bearing Housing Shaft Face Seal
  • 2. Install Shaft Coupling Assembly In Bearing Housing
  • E. Assemble Continued
  • 5. Install Alignment Studs In Bearing Housing And Shaft Assembly
  • 7. Align And Install Gear Set Onto Bearing Housing And Shaft Assembly
  • 9. Install Valve Plate Onto Gear Set
  • 11. Assemble Compression Springs, Preformed Packing, And Gasket Into Valve Housing
  • 12. Install Counterbalance Weight Assembly And Face Seal Rings Into Valve Housing
  • 13. Install Valve Housing And Counterbalance Weight Assembly Onto Assembled Valve Plate
  • 15. Install Check Valves And Fill/Drain Plug. Fill Auger/Conveyor Motor With Hydraulic Oil
  • 16. Assemble Auger/Conveyor Motor, Shim, Drive Sprocket Wheel, And Motor Mount
  • 1. Install Auger/Conveyor Motor Onto Paving Machine Main Frame
  • 2. Align Auger/Conveyor Drive Sproc- Ket Wheel With Auger Sprocket Wheel And Conveyor Sprocket Wheel In The Auger/ Conveyor Drive System And Connect Auger/Conveyor Drive Chain.
  • 3. Install Top Chain Cover Plate And Elbows.
  • 4. Connect Hydraulic Hoses To Auger/Conveyor Motor In And Out Ports.
  • 5. Connect Screed Extension Cylinder Return Line To Return Manifold. Connect Screed Vibration Solenoid Valve Tube To Screed Vibration Solenoid Valve
  • 6. Install Screed Extension Cylinder Extend And Retract Hydraulic Hoses. Install Screed Vibration Control Valve And Valve Tubes.
  • 7. Connect Left Side Screed Burner Fuel Line, And Screed Hydraulic Hoses And Tube To Straight Adapters.
  • 8. Install Inboard Battery
  • 9. Adjust Auger/Conveyor Drive Chain Tension And Replace Top Chain Cover Plate Onto Auger/Conveyor Drive Chain Housing
  • 10. Install Screed Harness Electrical Receptacle.
  • 11. Replace Cover
  • 2.70 Repair Screed Lift Cylinder
  • 1. Remove Retaining Ring
  • A. Disassemble - Continued.
  • B. Clean.
  • C. Inspect
  • 2. Inspect Piston Rod
  • D. Repair.
  • E. Assemble
  • 2. Install Packings And Seals
  • 3. Reassemble Piston Components
  • 4. Assemble Piston And Screed Lift Cylinder
  • 5. Install Retaining Ring
  • 2.71 Replace Main And Extension Screed Plates.
  • 2. Clean Area Between Screed Frame
  • B. Remove.
  • 2. Align Extension Screed Plates Flush With Main Screed Plate
  • 4. Lower Screed To The Ground And Remove Fasteners From Main And Extension Screed Plates
  • Removal Comments
  • 5. Remove Screed Plates From Main And Extension Screeds With Screed Raised.
  • 2.71 Replace Main And Extension Screed Plates - Continued.
  • 1. Inspect Screed Plate For Bowing Or Surface Distortion
  • 1. Clean Screed Base
  • 3. Assemble Screed Plate To Screed
  • D. Replace - Continued
  • Removal Comments
  • 2.72 Repair Screed Extension Cylinder
  • A. Disassemble.
  • 3. Remove Piston And Cylinder Head From Piston Rod
  • 4. Remove Seal And Packing Retainers From Piston.
  • B. Clean
  • C. Inspect
  • 3. Inspect Cylinder Head
  • 5. Clean All Metal Parts After Inspection.
  • 1. Press Out Spherical Bearing From Cylinder Tube Base
  • 1. Install Compression Cup, Ring Wiper, Packing Retainer, And O-Ring Into Cylinder Head
  • 2. Install Seal And Packing Retainers Onto Piston
  • 3. Reassemble Piston Rod
  • 4. Insert Piston Rod And Cylinder Head Into Screed Extension Cylinder
  • 5. Secure Cylinder Head With Retaining Ring
  • 2.73 Replace Extension Screed Guide Shaft Support, Guide Shafts, And Sleeve Bushings
  • 1. Remove Thickness Control Assembly
  • A. Remove - Continued
  • 1. Clean Guide Shafts, Guide Bars, And Guide Shaft Support
  • 2. Clean Mounting Hardware
  • C. Inspect
  • 2. Install Guide Shaft Support Assembly And Guide Shafts Into The Paving Machine
  • D. Install - Continued
  • 3. Install Thickness Control Assembly
  • 2.74 Replace Main Screed Vibrator Components
  • 2.74 Replace Main Screed Vibrator Components.
  • 2. Remove Motor Mount, Retainer Plate, And Bearing Plate.
  • 3. Remove Bearings From Bearing Plate And Motor Mount
  • 1. Clean All Metal Parts.
  • C. Inspect
  • D. Install
  • 2.74 Replace Main Screed Vibrator Components - Continued
  • 3. Install Bearing Plate, Retainer Plate, And Motor Mount
  • 4. Install Universal Joint On Drive Shafts
  • 2.75 Replace Extension Screed Vibrator Components
  • 1. Remove Motor Mount, Retainer Plate, And Bearing Plate
  • 2. Remove Bearings From Motor Mount And Bearing Plate
  • C. Inspect.
  • 2. Inspect Drive Shaft For Damage.
  • 2.75 Replace Extension Screed Vibrator Components
  • 2.76 Repair Screed Vibration Motor
  • A. Disassemble
  • 3. Remove And Disassemble Motor Shaft
  • 4. Remove Check Valve And Needle Bearing From Motor Cover
  • B. Clean
  • C. Inspect
  • 3. Inspect Motor Shaft, Outer Gerotor Gear, And Inner Gerotor Gear
  • 2. Install Needle Bearing And Check Valve Into Motor Cover
  • 3. Assemble And Install Motor Shaft.
  • 4. Install Motor Mounting Plate, Encased Seal, And Preformed Packings
  • 5. Install Elbows And Preformed Packings.
  • 2.77 Replace/Repair Screed Vibration Flow Divider
  • 2. Clean Screed Vibration Flow Divider And Elbows
  • 3. Remove Screed Vibration Flow Divider From Screed
  • B. Disassemble.
  • 1. Inspect Body
  • E. Assemble
  • 2. Install Preformed Packings, Plugs, And Elbows Onto Body
  • F. Replace
• Appendix A References
  • References -Cont
• Appendix B Expendable And Durable Items List
  • Section Ii. Expendable And Durable Items List
  • Expendable And Durable Items List -Cont
  • Expendable And Durable Items List -Cont
• Appendix C Illustrated List Of Manufactured Items
  • Section Ii. List Of Manufactured Items
  • Figure 1. Alignment Stud
  • Figure 2. Centering Jig
  • Figure 3. 2.75 In. Diameter Driver
  • Figure 4. 3.5 In. Diameter Driver
  • Figure 5. 4.5 In. Diameter Driver
  • Figure 6. Input Bearing Driver
  • Figure 7. Flywheel Guide Pin
  • Figure 8. Hollow Pipe
  • Figure 9. Lock Nut Torquing Adapter
  • Figure 10. Mandrel
  • Figure 11. Mandrel
  • Figure 12. Mandrel
  • Figure 13. Mandrel
  • Figure 14. Pinion Stop Support Block
  • Figure 15. Shaft Bearing Removal Tool
  • Figure 16. Shaft Face Seal Tool
  • Figure 17. Shaft Face Seal Tool
  • Figure 18. Shaft Seal Assembly Tool
  • Figure 19. Shaft Seal Driver Tool
  • Figure 20. Shaft Seal Bullet
  • Figure 21. Shaft Seal Installation Tool
  • Figure 22. Spacer Wedge
  • Figure 23. Support Cylinder
  • Figure 24. Track Frame Offset Wrench
  • Figure 25. Valve Seat Installation Tool
  • Figure 26. Valve Sleeve Installation Tool
  • Figure 27. Straightedge
• Appendix D Tool Identification List
  • Section Ii. Tool Identification List
  •  Tool Identification List -Cont
  •  Tool Identification List -Cont
  • Tool Identification List -Cont
  • Tool Identification List -Cont
  • Tool Identification List -Cont
  • Tool Identification List -Cont
• Appendix E Torque Limits
  • Section Ii. Torque Limits For Cap Screws And Bolts
  • Tightening Torque - Metric Class 8.8
  • Section Iii. Torque Limits For Set Screws
  • Alphabetical Index
• Index -Cont
  • Index -Cont
  • Index -Cont
  • Index -Cont
  • Index -Cont
• The Metric System And Equivalents

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