OPERATOR’S MANUAL With Service Schedule and Specifications FOR DM-5500 PAVER/FINISHER Pub. No. DM-5500-OP-9-00-500 Part No. 21870902, 1st Edition Fad this instruction manual before operating this equipmentDM-5500 INTRODUCTION READ THIS MANUAL CAREFULLY to leam how to operate and service the DM-5500 ‘Asphalt Paver. Failure to do so could result in personal injury or equipment damage. Con- sult your Ingersoll-Rand/Blaw-Knox Distributor. if you do not understand the instructions in this manual or need additional information THIS MANUAL should be considered a permanent part of the Asphalt Paver and available for reference at all times, WARRANTY Js provided as part of Ingersoll-Rand/Blaw-Knox’s support program for customers who operate and maintain their equipment as described in this manual. Refer to the warranty page ofthis manual for detailsINTRODUCTION DM-5500 MACHINE RECORD Date Purchased Machine: Model Seria No, Pub. No. Engine: Make Model Seria No, ‘seved: Model Serial No. Pub. No. Options: Name Serial No, Pub, No. NoTes ‘The warranty fortis pavertinisher appears inside the front cover of this mani Important: Record the serial number of your machine, engine, and options above, as well as publication ‘umbers of related Operators Manuals and Parts Catalogs. This formation wil assist you in the ute ‘nen obtaining service advice o¢repa pats fox your machineDM-5500 TABLE OF CONTENTS Co ead this instruction manval before operating this equipment. GENERAL SAFETY PRACTICES. CAUTION AND WARNING SIGNS (Location and Content) LOADING AND UNLOADING INSTRUCTIONS. DRIVE OFF PROCEDURE ‘SAFETY PRACTICES FOR OPERATING PAVER OPERATING INSTRUCTIONS. BLB13 ‘Operators Consoles, Controls & Instruments 81-87 ‘Screed Adjustment Jacks BB Paving withthe DM-5600 59.810 Pre-Operation Checkout Procedure 11-813 Start Up Instructions, 11-813 ‘SERVICE AND ADJUSTMENTS cv; ‘SAFETY PRACTICES FOR SERVICING PAVER Lubricants Lubsication and Service Schedule ‘c3.c3 lean Up and Wash Down Procedure cacs Preventive Maintenance Checklist cs ‘Track Replacement er-c9 “Track Adjustments C10 Off Season Storage on MACHINE SYSTEM INFORMATION 1-06 Periodic Maintenance Schedule 2| ‘Troubleshooting 03-05| Specifications, De|GENERAL SAFETY PRACTICES DM-5500 BE AWARE OF SAFETY INFORMATION This isthe Safety Alert Symbol. When you see this symbol in this manual, be alert to the Potential for personal injury Follow recommended precautions and safe operating practices UNDERSTAND SIGNAL WORDS [A signal word - DANGER, WARNING, or CAUTION -is used withthe safety alert symbol DANGER identities the most serious hazards. DANGER, WARNING, or CAUTION. safety labels are located near specific hazards INOIIGE labels are for ganeral information. SAFETY ALERT SYMBOL DANGER IS USED TO INDICATE THE PRESENCE OF A HAZARD WHICH WILL CAUSE SEVERE PERSONAL INJURY OR DEATH IF THE WARNING IS IGNORED. 4 WARNING WARNING IS USED TO INDICATE THE PRESENCE OF A HAZARD WHICH CAN CAUSE SEVERE PERSONAL INJURY OR DEATH IF THE WARNING IS IGNORED, 4A CAUTION CAUTION IS _USED TO INDICATE THE PRESENCE OF A HAZARD WHICH WILL OR, CAN CAUSE SEVERE PERSONAL INJURY, ‘OR PROPERTY DAMAGE IF THE WARNING |S IGNORED. NOTICE Notice Is used to notily people of instalation, ‘operation, or maintenance information which is Important but not hazard related.DM-5500 GENERAL SAFETY PRACTICES ‘The DM-5500 Blaw-Knox Asphalt Paver has been carefully designed and manufactured to provide the utmost in dependable service. To ‘obtain the best resus and keep the machine ‘operating efficient, read and folow the instructions in this Operators Manual ‘This machine has been factory tested and lubricated, and initial setings and adjustments carefully made. However, it is recommended that a thorough inspection of the entra machine be made prior to starting, to correct any problems which may have occurred in transit Designing and manufacturing a sale machine is of primary concern to Blaw- Knox. Shielding, simple adjustments, and other safety features were bult into this paver wherever possible. NOTICE ‘All machinery should be operated and serviced ‘oniy by responsible persons who nave Deen propery instructed and authorized to do so. Read and understand all instructions contained in this manual, the engine manual and all ‘optional equipment manuals before attemating 10 operate or service the asphalt paver ‘Only the operator should be allowed on the ‘operator's platform when the machine is in ‘operation. ‘Always mount and dismount the machine from the rear Be sure that the direction-speed levers and all function switches are in the OFF or NEUTRAL positions before starting the engine. All main Switches must be ON. keep operator's platform clean, Do not use it as ‘a place to cary loose tools, lunch boxes, etc Before leaving the operators platform, always be sure that all control switches are in the OFF or NEUTRAL positon, hopper wings are lowered, screed is lowered or secured in the ralsed postion, and the engine is shut of A CAUTION All persons working close to the asphalt paver should wear close fiting, belted clothing, Loose clothing could be caught in moving part. Be sure all shields and guards are in place and in good condtion before start-up on the job, Make sure everyone is clear of the machine before starting 80 they cannot be struck or caught in moving pats. FRefil the radiator only when the engine is stopped or idling slowly. This asphalt paver has a pressurized cooling system. To avoid being Scalged when radaior cap Is removed wear Gloves or use a heavy rag. Then tum cap slightly to the stop which allows steam to escape through the overtiow pipe, Afr all pressure is relieved, remove cap.w GENERAL SAFETY PRACTICES DM-5500 Do not alow passengers on the machine, Refuel the machine only when the machine has been shut off. Do not permit sparks, open flames, or smoking within 50 feet of the machine when refueling. Never refuel the ‘machine with screed heaters operating, Do not cut hopper spi guards with a cutting torch of open flame. Toxic fumes will be gonerated Never use the wash down system when the screed heaters are operating, Escaping hydraulle fluid under pressure can have sulficient force to penetrate the skin causing serious. personal injury. Before sisconnecting @ line, be sure to relieve all pressure. Betore applying pressure to a system be sure all connections are tight and that lines, tubes and hoses are not damaged. Fluid ‘escaping from a very small hole can be almost invisile. Use a piece of cardboard or wood, Famer than hands, to search tor suspected leaks. If injured by escaping fuid, see a doctor at ‘once. Serious infection or reaction can develop it proper medical treatment is not administered immediately. Never clean, lubricate, or service the paver finisher when iis running. TAKE TIME TO BE SAFE!DM-5500 SAFETY SIGNS (Location and content) |AWARNING| aN -~ ‘sDM500| DO NoT TRANSPORT PERSONNEL OR ALLOW PASSENGERS ON THIS MACHINE 4S WARNING IMPORTANT: Machine owner should maintain all safety signs in legible consition.LOADING AND UNLOADING INSTRUCTIONS LOADING DOCK WITH RAMP: PREFERRED Before starting the machine, read the De dive Off Procedure RAMP BOARDS: IF NECESSARY W'no loading dock is av a set of ramps positioned at a 14 degr may be used. A WARNING | , over, always back the paver up Bo sure the ramps are rated to cary a load of 6 tons (57) First remove any separate parts from the truck bed. Then, remove all of blocks, and blocks undé fown equipment, chock Before starting the machine, read the Drive Off Procedure (CRANE LIFT: WHEN AVAILABLE ‘Then, remove all of the tie down equipment, chock blocks. Lif the machine clear ofthe truck 'bed and lower tothe ground Before starting the machine, ead the Drive Of fh Procedure DM-5500DRIVE OFF PROCEDURE DM-5500 4. Mount the machine using the operator's piatform provided atthe rear of the machine. 2. Koop the operators platform clean. Do not Use it as a place to carry loose tools, lunch boxes, ete. 2, Be sure that all shields and guards are in place and in good condition before start-up. 4, Check to be sure that the engine oll is at proper level (reer to engine marial) and that there is fuel in the tank. 5. Be sure that all ofthe hydraulic contol levers. fare in the center positon. The machine may move immediately when the engine is started if the Hydraulic Steering Control Levers are ‘engaged. 6 Sat_the_ engine approximately % trot, ‘speed control to 7. Insert the key in the ignition switch (Fig. 1) and turn ‘the key fully counter clockwise and hold for approximately 15-20 ‘seconds to allow the glow plugs inthe engine to heat up and assist in easier stating, A CAUTION Never start or attempt to start the engine without heating the glow plugs. Doing so could ‘cause severe engine damage 8, Press the Safety Circuit Bypass Switch (2, Fig. 1) while turing the key fully clockwise to fengage the starter. Release the switch and release the kay (to the ON positon) when the engine starts 8. If the screed (the large assembly at the rear of the machine) isnot alteady supported above the ground, push the Screed Lift Lever to RAISE and fold it there until the screed is totally raised. The screed will remain raised when the spring loaded switch is released and returns to HOLD. 10. To move the machine, push the Hydraulic Steering Control Levers (1, Fig. 2). slowly FORWARD or REVERSE as required. You ‘must lit the release to move the levers. The further the levers are moved, the faster the machine will travel 114. To stop the machine, bring the Hycraulic ‘Steering Control Levers back to NEUTRAL. 12, lum the key counterclockwise to the OFF positon. Figure 2DM-5500 DRIVE OFF PROCEDURE Blank PageDM-5500 OPERATING INSTRUCTIONS aSAFETY PRACTICES FOR OPERATING PAVER DM-5500 Read and understand all instructions Contained. in this manual, the engine manual and all optional equipment manuals betore attempting to operate the asphalt paver. The machine should be ‘operated only by an operating engineer or the equivalent. ‘Always mount and dismount the machine from the rear using the platform provided. ‘Only the required person at histher proper work Staton ara to ba on the machina, Be certain that the Direction-Speed Control Levers are in the NEUTRAL postion before starting engine Reduce travel speed by moving the Direction- Speed Control Levers before stopping machine. Bofore leaving the operators otation, always bo sure that all Control Switches are in the OFF oF Neutral position, and the screed is lowered oF secured inthe raised positon and the engine is. shut of keep the operator's platform clean. Do not use itas a place to carry loose tools, lunch boxes, ate CAUTION ‘Check all functions of the asphalt paver for proper operation. Never attempt to use a maifunetioning machine Accidents Don’t Just Happen. They are Caused! Be Careful! Be sure al shields and guards are in place and in good condition before operating the asphalt paver. Make sure everyone is clear of the asphalt paver before staring so they cannot be struck fr caught in moving parts. Never permit anyone fo cmb or stand on the ‘machine except onthe platform provided, Keep all persons clear of augers, hoppers, conveyors, side arms, power widening screed fends, and tuck hitch when operating the asphalt paver. Never permit anyone to remove paving material ‘rom the hopper or augers wiile the asphalt paver is operating Never attempt to attach or remove any part or asgembly on the machine while its running. Never use the wash down system when screed heaters are operating Refuel the machine only when engine has been shut off. Do not permit sparks, open flames or smoking within 50 feet of the machine when Felueling, Never refuel the machine with screed heaters operating Never clean, lubricate or service the asphalt paver when itis running, 42DM-5500 OPERATION atOPERATION DM-5500 OPERATOR'S CONSOLES, CONTROLS, AND INSTRUMENTS. DIRECTION-SPEED CONTROL LEVERS (1 & 2, Fig. 1) are hydraulic actuators which contol the direction of ‘machine travel ‘STEERING-FORWARD-STOP-REVERSE land vary the speed within the limits of the Single speed traction drive motor and single speed transmission. An instruction plate Indicating these postions is attached to ‘each console. Figure ‘These speed control levers are equipped with neutral postion locks which are spring loaded To engage the levers, the lock release rings located just below the knob must be hited to move the levers to @ FORWARD or REVERSE position Under normal paving conditions, both levers are moved forward unti the desired pav- ing speed is achieved, Stoeringis then accom- plished by pulling back slightly on the control lever on the side of which you want to turn. This action will slow down the track on that side and will cause the paver to turn in that drac- ton. tis not desirable to tur by moving one track wile dragging the other. This practice requires ‘more power and can result in premature track wear. It's possible to counter rotate the paver (turn around in the same postion) by pushing ‘ne track steering control forward and pling ‘one control in rovers A WARNING The Direction-Speed Control Levers must be in NEUTRAL to start the engine Handle Position _—_-Funetion t FORWARD Forward . stop Neutral | reverse raveDM-5500 OPERATION MAIN POWER SWITCH (1, Fig. 2) is the master switch for all circuits ‘on the machine. This switch must be ON, Key installed, to operate electrically controled functions. This ‘switch should be OFF, when the machine is unattended. WARNING LIGHTS (2, Fig. 2) are used to monitor the Alternator Output, Oil Pressure, land Water Temperature when the engine is ‘operating. The Alternator Light willbe It # the lalternator Is not generating adequate current to charge the battery. The Oil Pressure Light wi be litt ol pressure is inadequate to lubricate the main bearing in the engine. The Water ‘Temperature Light willbe lt it engine coolant {temperature reaches an unsate level Figure2 If any of these lights remain ON after starting the engine, shut down the machine and remedy the problem before continuing SAFETY CIRCUIT BYPASS SWITCH (3, Fig 2) is a button that must be pushed during'start up. Pushing the switch by passes the engine oll pressure safety circuit allowing the engine to start and bull of pressure. If the engine oll pressure falls below the minimum allowable, oF {tthe engine coolant exceeds the maximum allowable temperature the safety shut down system will activate, shutting down the engine {and iluminating the appropriate lamp indicating the reason for shutdown, BsBs OPERATION DM-5500 AUGER CONTROLS (1, Fig. 3) activates the ‘operation of the material augers. Each auger has one AutofManual Switch, and one OwvOtiin ‘witch. In the automatic positon, the augers wil ‘automatically operate any time the conveyor is, running. With the switch in the Manual position, the auger will run continuously independent of the conveyor. The augers are normally not re- ‘uired at paving wicths of less than 7 feet. Be- yond 7 foot paving widths, the augers should be fun to insure proper feeding of the extended ‘screed. The OwvOfliIn switch controls the di ection the augers move the material. With the ‘switch in the Out position the augers move the material away from the hopper toward the ‘screed. When the switch is placed inthe In_po- ‘sion, the material is moved toward the hopper. When the switch is in the Off postion, the au- ‘gers do not move materia i Qiao) Figures ‘switeh t | our ‘Augers mater ut Position OFF ‘Augors of auTo. MAN " Augers ‘moving materia Function Automatic operation Manual operation Position ‘switch FunetionDM-5500 OPERATION CONVEYOR Controls (2, Fig. 3) are used to operate the two 18° independently controled conveyors. The conveyors move the asphalt from the hopper to the screed. Since the conveyors are independently driven, ether conveyor can be operated while the other is stopped, allowing paving wits from 2 1/2' to 4 With the switch in the automatic postion, the conveyors are controled by the asphalt level control paddles mounted on each edger plate (1, Fig 4). Figures Switch Position Funetion t AvTO. Automatic . 1 Man anual 85OPERATION DM-5500 Figures SCREED CONTROLS (1, Fig. 5) acvato the various sereed functions.’ The Nanda on the Handle Position {ar let controls the extendible function othe It sereed extension (being other OUT or IN). t our “The handle onthe far ight of the machine con trols the extension ofthe ight side (ether OUT . OF IN). The augers should alvaye be tumed on ‘when paving t " Funetion Extended RoactesDM-5500 OPERATION SCREED LIFT CONTROL (2, Fig. 5) The ‘screed control handla lowers or raises the ‘screed. Pushing the handle to the Lower or Raise position moves the screed accordingly. Releasing the handle holds the sereed in the ‘established positon Handle Position Function t LOWER Lowers Screed ° CENTER Hold Position ' RAISE —Pales Soeed HOPPER CONTROL (3, Fig. 4) controls the hopper wings. Pushing the handle up folds the wings in and feeds paving materials into the conveyors. Pushing the handle down folds the Wings out for loading ofthe hopper. The lever is Spring-loaded to return to the center position, Handle Position Function t CLOSE Feed Conveyors e CENTER Hod Potion 1 OPEN Lond Hoppers 87OPERATION DM-5500 Figures VIBRATORY SCREED (4, Fig. 5) Is used to provide. addtional compaction to the asphalt, Handle Push the handle upto stat the vibratory sereed ‘and push the handle down to stop the vibratory =f screed. It's recommended that the Vibrator Function be used only wnen necessary to conserve horsepower for all ther functions. Be sure the cylinder is completely lowered when 1 paving, Position Function on Vibration ofr No VibeationDM-5500 OPERATION SCREED ADJUSTMENT JACKS (1, Fig. 6) Which are located on each sida of the sored, fre used to control the paving depth, by controling the angel of attack. Turning the handles clockwise increases the paving depth. Turing the handles counter clockwise docreases the paving depth Figures Recommendations: ‘The start up procedure for setting the screed angle of attack is to raise the front of th screed slightly during the inital pull unt the desired level is obtained. The long tow arms are designed to average out transition in the grade. After the adjustment is made, and it the base is wel prepared and flat, only minor adjustments should be necessary IMPORTANT: Constant adjustment of the screed angle wil lead to an uneven mat and should be avoided,OPERATION DM-5500 PAVING WITH THE DW-5500 use the following information to begin paving with the Blaw-Knox DM-5500. OPERATING THE DIESEL WASHDOWN SYSTEM (1, Fig. 7), The diesel washdown system is used in preparing the paver for receiving asphalt. The diesel fue! prevents the asphalt from sticking to the paver and allows ‘the material to side down through the hopped ‘conveyors and out through the augers to the sored, It also assists in cleaning and maintaining the paver. Figure7 Spray Switch (1 Fp on the Diese! Fig. 8) to activate the fuel purnp. Diese fuel wil, flow to the wand assembly. To spray, the ‘Trigger on the spray wand is pulled Figure 8 Before filing the hopper with asphalt, use the ‘iesel washdown system to thoroughly coat all areas of the hopper, conveyors and flow gates ‘that come in contact with asphalt It is also desirable to coat the bottom of the screed and all other areas where asphalt build Up is a problem. Its important that the track system be kept well lubricated, You should spray both tracks with diesel fuel at least daily ‘Tracks that are not propery lubricated require too much power from the engine. After the paving is completed, use the diesel washdown system {0 clean up any asphalt residue. Cleaning the paver before and after paving will increase the if of the machine, OPERATING THE DM-5500 WITH A DUMP TRUCK Move the paver into position and back| the dump tuck up to within two to five inches of the paver. If the paver is equipped with an selling push bar (1 Fig, 9), back the dump {tuck up Until the tres contact the push bar. Figure Be sure that the hopper wings are fully ‘open before allowing the dump truck to begin dumping asphalt into the hopper. ‘As the hopper approaches being filed, signal the truck operator to lower the ‘dump. Tum the conveyors and augers on automatic and allow the asphalt to build to the proper height infront of the screed. B10DM-5500 OPERATION ADJUSTING THE SCREED FOR CROWN OR, INVERT PAVING The screed on the paver can be adjusted for paving with a crown or valley (inven). The normal use is for maintaining water Grainage. Adjusting the screed for crown or invert is done by igntening (invert) or loosening (Grown) the screed crowrvinvert jack (1, Fig 10). “There is a handle located in the canter of the jack to assis in this operation ADJUSTING THE JOINT MATCHING SHOES In normal paving with screed extensions fully retracted and not paving adjacent to previously paved areas the shoes should be inthe floating Position. This is accomplished by loosening the shoe hold down tabs (1, Fig. 11) just enough thatthe shoes can move up and down, PAVING WITH SCREED EXTENSIONS EXTENDED For paving extended widths, variable widths, or paving adjacent to curbs, buildings, etc. itis useful to extend the screed ‘extension(s). Extensions are adjusted by the Ssexeed extension conta. Under normal operation the auger Manual ‘Automatic contral switch is placed inthe ‘Automatic position. The Auger Directional ‘control switches are placed in the Forward or ‘Out poston. In this mode of operation the augers will tun anytime the ight or left ‘conveyor is activated to maintain the proper ‘strbution of asphalt tothe extensions. For special applications the augers can be ‘operated manually by placing the Manual / Automatic Switch i Uve Matnual position ard te Auger Directional Control switeh in either the ‘OUT or IN postion. When operating the ‘augers in the Manual mode, the auger should be tumed OFF once the extension(s) is filled with asphalt. Continuous running of the augers ‘can cause the mat to be uneven and shorten the life of the augers.OPERATION DM-5500 PRE-OPERATION CHECK-OUT PROCEDURE Before starting to pave with the DM-S500, the machine should "be inspected using | the following check ist as a guide: 41. Before starting, engine lubricating oil evel 2. Before stating, engine coolant water level 4 Before stating, hydraulic reservotr fig level 4. Before stating, machine lubricated per instructions inthis manual '5, All machine functions operating property ‘Also check the following tems periodically or ‘where applicable, ee lubrication chart 8 Planetary fud levels. 8, Engine fuel and airfiters. Engine properly tuned and operating smoothly. Fan belt tight 410, General purpose hydrauiic pressure. 11. Conveyors adjusted properly and wear check, Also see Wear Check Manus 12, Augericonveyor drive chains adjusted propery and auger waar check. Alco coo Wear Check Manual, ‘START UP INSTRUCTIONS 41) Aftor the paverfnisher arives atthe job site, ‘when preparing to lay bituminous base materials and if paving specifications perm, Use the machine's wash down hose to wet al surfaces with fuel oil which will come in Contact with paving material (push ols, hopper, conveyors, augers, screed face and bottom as well as screed extensions and ‘edger plates). This will make clean up easier. A WARNING Never use wash down spray wile screed heaters are operating 2) Position the machine on the joint or point from which paving is to start. Screed extensions ‘should be appropriately adjusted if the job requires their use. Feed control sensors ‘should be installed, Position the steering ‘Guide in relation tothe steering reference, 3) Initaly set the flow gates 1/2. open. Final precise adjustment is made after paving has ‘Startad and material damand on each side of the screed versus supply is observed. 4) When starting o lay a bituminous mat, i ie ‘essential that the bottom of the screed be ‘elevated from the grade a distance equal to the desired mat depth plus enough extra height to allow for mat compaction by roling, This Is normally accomplished by” placing wood starting blocks of the required thickness under each end of the screed. Example: Ifa fiished mat of 2" (51 mm) is to be lad, starting blocks 2's" (65 mm) thick ‘would provide a sutable starting height. Note that starting to pave ftom the end of a previously laid mat, staring blocks with a thickness equal only tothe amount. of ‘compaction are all that is required (i) [14 rm] with reference tothe foregoing exam, 8) The starting blocks should be as long or longer than the cimension of the sereed plate (front to rear) and should be placed longitudinally with the pavers direction of travel, one under and near each end of the sereed, This staring block placement wil provide the screed plate with a full bearing surface on each end that is essentially parallel with the grade and on which the Screed can be ruled out erDM-5500 OPERATION 6) Null out the screed. This is an expression used to describe adjusting both ends of the screed 50 that the screed plate rests ‘absolutely fat on the stating blocks. When both the front and rear edges of the screed plate rests squarely on the starting blocks the screed depth cranks will have a limited amount of free rotary movement between ‘screw tension in ether direction, Tne Presence of this free rotary movement in both screws indicates that the screed is ruled out 7) Introduce screed angle of attack. The weight ‘ofthe screed exerts a compacting force as it passes over the bituminous mix. Angle of attack Is an adjustment which raises. the {ont edge of the sereed causing the sereed to climb enough to equal the amount of ‘compaction that It exerts on the mix. Exact langle of attack is always an unknown factor since many factors such as variations in mix, composition, temperature and paving speed all affect the amount of angle of allack requited. However, is known Ut there will be compaction by the screed making it necessary to introduce some ‘angle of attack before the screed leaves the starting blocks, With the screed properly nulled out, introduce start-up angle of attack by turing both screed depth cranks one full turn counter-lockwise (CCW), When paving begins check mat depth land adjust the depth cranks until desired mat depth is obtained. 8) Light the screed heater and preheat the sereed per the instructions given in the ‘Screed Manual. 9) Position a truck loaded with paving material against the push rolls in front of the paver. ‘Adjust the throttle, and turn both the Auger ‘and Conveyor switches to AUTO. Fill the hopper and allow the augers to fil up and stop. If necessary, tum the screed vibrator ON. Move _ the _Direction-Speed FORWARD and begin to pave. 10) Levers 11) As paving progresses, make adjustments necessary to maintain adequate material Gelvery ind produce a salisactory al 12) Refer to the Blaw-Knox PAVING MANUAL for information on Controling Mat Quality 13) Refer to Figure 12 for a guide to amounts ‘of paving material needed. B13OPERATION DM-5500 Mix needed to cover a square yard Densiy of rmivios Pee] | oa faa oF 150 nse us sss 0 nses Bs nso 10 ose Square yard area covered by one ton of mix Inches of thickness Density of times} 2 | ot fran] 2 fa fa |s fo fs fo | 2 fos hs Per cure 155 Tae | 0956 0 1s 10 Figue 12 enDM-5500 SERVICE AND ADJUSTMENTS. acn SAFETY PRACTICES FOR SERVICING PAVER DM-5500 Read and understand all instructions ‘contained. in this manual, the engine manual and all optional equipment’ manuals, before attempting to service the paver. Paver adjustments and servicing should be performed ‘only by responsible persons who have been propery instructed and authorized to do so. NOTICE Always mount and dismount paver from the fear, using walkways, steps and handrails provided. A WARNING Before attempting to service, attach or remove ‘any part or assembly on the paver, make certain that: (7) Al-controls and switches are in the OFF or Centered position. (2) Hopper wings are lowered (@) Screed is lowered or secured in the raised position, (4) Engine Instructed Is shut off unless otherwise FRafuel paver only when engine has been shut off. Do not permit’ sparks, open flames or ‘smoking within 50 feet of the paver when felueling. Never refuel paver with screed heaters operating Never use the wash down system when screed heaters are operating Escaping hydraulic fluid under pressure can have sufficient force to penetrate the skin causing serious personal injury. Before tisconnecting @ line, be sure to relieve all pressure. Before applying pressure to a system be sure all connections are tight and that lines, tubes and hoses are not damaged Fluid escaping from a very small hole can be almost invisible, Use a piece of cardboard or ‘wood, rather than hands, to search for suspected leaks. Hf injured by escaping fluid see a doctor at ‘once, Serious infection or reaction can develop if proper mecical treatment is not administered immediataly A CAUTION Refil the radiator only when the engine is stopped or idling siowly. This paver has a pressurized cooling system. To avold being Scalded when radiator cap is removed, wear gloves or use @ heavy rag. Then tum cap Slightly to the stop which allows. steam to escape through the overflow hose. After all pressure is relieved, remove cap. Pour coolant in slowly until level is 1" below the bottom of filer neck Batteries produce explosive gases. Keep all sparks and open flames away from batteries, if 4 battery needs recharging, avoid sparks by tuming "off the chafger’ before making ‘connections or disconnections Sulfuric acid in batteries is a poison and could ‘cause severe bums. Avoid contact with skin, eyes and clothing. When working around batteries, protect eyes and face from battery fluid and possible explosion. Before starting the engine, be sure there is ‘adequate ventilation. if it i necessary to ‘operate the engine inside an enclosed service ‘area, be sure exhaust is properly vented Make sure everyone is clear of the paver before starting 50 they cannot be struck, or ‘caught in moving partsDM-5500 SAFETY PRACTICES FOR SERVICING PAVER ‘CLEAN UP AND WASHDOWN PROCEDURE To ensure proper performance and maximum service life of the paver, it must be cleaned and washed down with ciasel fuel, Kerosene, or ‘other appropriate cleaning solution at the end of feach work day while the machine is stil warm. Daily clean up of the paver can signioantly Increase the lite of components in the material handling ateas and reduce many mat problems. Abrasive materiale which accumulate in ‘Sprocket, bearing, auger and conveyor areas increase’ the stress on all components and accelerate wear. Cold paving material can break loose and produce tears inthe mat as they pass Under the screed. Al residual asphalt materials. should be removed trom the paver, especially in the material handling areas, and the surfaces sprayed to eliminate any remaining residue This leaves a petroleum fim on surfaces to reduce the potential for material sticking the ‘ext time the paveris used. ‘The clean up and washdawn procedure should bbe performed away from the paving site. The paver should be driven to the dasignated areas {and the folowing shutdown procedure used: Bo sure everyone is clear of the machine, Lower hopper wings or bed ‘Secure seread in raised position. Make sure all functions are shut OFF. ‘Allow sereed heaters to cool 10 minutes before washing screed. ‘Secure screed in the raised postion vith support. A WARNING Never wash down the machine while the screed heaters are operating, This could resutin fie or explosion Naver smoke or allow others to smoke wile washing with fuel oll or kerosene, This could result in fire or explosion Run the conveyors and augers. only when required to gain access to all surfaces and only after personnel are (ut of the material handling areas. Never stand in the hopper while the {engine is running Diesel fuel is both flammable and slippery, So extreme care must be exercised during this clean up and WASHDOWN procedure to avoid fire (personal injury. Spray down all surfaces which come in contact with paving material. Then use a scraping