OPERATION AND MAINTENANCE MANUAL Ingersoll-Rand Blaw Knox PF-161 Paver/Finisher Read and understand this manual before operating or servicing this equipment.CALIFORNIA Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.TABLE OF CONTENTS TITLE INTRODUCTION PROCEDURE WHEN RECEIVING THE MACHINE. IDENTIFICATION DATA| MACHINE IDENTIFICATION GENERAL INFORMATION. MACHINE DESCRIPTION ENGINE ELECTRICAL SYSTEM HYDRAULIC SYSTEM FUEL SYSTEM COOLING SYSTEM BRAKES . : TRACTION DRIVE TRACTION LOCK SYSTEM PIVOT STEERING ... REAR SUSPENSION . FRONT SUSPENSION OPERATOR'S UMBRELLA TRUCK HITCH POWER FLOW GATES. DUAL FEED SYSTEMS CONVEYORS. AUGERS AUTOMATIC FEED CONTROL SYSTEM MAT KONTROL® II WITH PADDLE SENSORS MAT KONTROLS II WITH ULTRA 3s® SENSORS ‘SMOKE-EATER® VENTILATION CONTROL SYSTEM WASHDOWN SYSTEM CONTROLS ..... SCREED CHOICES/SCREED OPTIONS. SCREED HEATERS . DIESEL ONLY HEATERS. ....0.... feces wee DIESEL HEATERS WITH AUTOMATIC TEMPERATURE AND IGNITION CONTR PROPANE (LPG) HEATERS WITH ATIC. WEDGE-LOCK® SCREED. WEDGE-LOCK® SCREED EXTENSIONS. 2,5I5B HYDRAULIC SCREED EXTENSIONS POWER SLOPE OPTION FOR 2.5/5B HYDRAULIC EXTENSIONS BERM ATTACHMENT OPTION FOR 2.5/5B HYDRAULIC EXTENSIONS OMNISCREEDS IA. GENERAL EQUIPMENT OPTIONS. Front Wheel Power Assist Option, Material Indicator Kit Option... .. Blaw-Kontroll® II Option . Untragye® V Grade Sensor Option ‘Automatic Level Control (Also Known as a Joint Matcher) Option Floating Beam Reference Option Mat Reference Option Additional Operator's Umbrella Option IDENTIFICATION OF MAJOR COMPONENTS (atic) ‘SECTION PF-161 PaveriFinisherTABLE OF CONTENTS TITLE SAFETY BE AWARE OF SAFETY INFORMATION ........ UNDERSTAND SIGNAL WORDS OVERVIEW. WARNINGS GENERAL. SELECTION AND QUALIFICATION OF PERSONNEL ORGANIZATIONAL MEASURES. MANDATORY SAFETY MEASURES. LOADING AND UNLOADING Loading Dock with Ramp (Preferred Method) Alternate Ramp Method : PRE-START INSPECTION, SAFETY INSTRUCTIONS GOVERNING OPERATION Starting Operating Stopping Maintenance. HAZARDOUS SUBSTANCE PRECAUTION WARNING OF SPECIAL DANGERS ASSEMBLY GENERAL. GENERAL ASSEMBLY. Before you Begin . fee Selecting a Site for Assembly... . Unloading the Machine. Installation of the Steering Guide . . Installation of the Edger-Plate Assemblies Installation of the Automatic Feed Control Sensors Installation of the Paddle Sensors Installation of Ultra 3s Ultra Sonic Sensors Muffler Installation OPTIONAL INSTALLATION GUIDELINES. Installation of the Cut-off Plate Installation of Additional Augers Installation of 1-foot Bolt-on Screed Extension Installation of the 18-inch Tapered-Joint Extension Installation of the 8-foot Wedge-lock Screed Installation of Ultrasonic 4 Sonic Averaging System/Sonic Joint Matcher Installation of the Ags (7.5) Controllers OPERATING CONTROLS AND INSTRUMENTS DIRECTION-SPEED CONTROL LEVERS ‘Steering Units MAIN CONTROL PANEL Engine Tachometer/Hour Meter Maintenance Indicator Wall to Start Indicator. ‘SECTION SaRESESES Las peegeggegeenreceggye 22 122 23 23 27 28 2.40 240 242 244 244 244 245 221 22-24 2.26 2:28 231 32 32 33 33 33 33 PF-161 PaveriFinisherTABLE OF CONTENTS TITLE ‘SECTION Water in Fuel Indicator. ..........cee0eeeeeeeeessesseeeeeee 234 Stop Engine Indicator 235 Check Engine Indicator . 236 Brake Engaged Indicator fees ceeeeee fee 236 Oil Pressure Gauge 35 Empty Tunnel Indicator. 35 Hydraulic Filter Light, 36 Water Temperature Gauge. 36 Battery Gauge 36 Oil Temperature Gauge 36 Front Wheel Assist Switch 36 Starter Button 37 Engine Kill Button . . cee : o : 37 Transmission Shift Switeh 37 Motor Shift Switch, : 238 RH Flowgate Control Switch. 138 LH Flowgate Control Switch . 38 Screed Control Switch : : ce feeeeee 38 ‘Auger Control Switch 38 Hopper Control Switch 38 Horn Button 38 RH and LH Conveyor Switches 3.9 Parking Brake Switch 3-10 ‘Screed Vibrator Switch 3-10 Governor Switch 3-40 Throttle Switch 3-40 Positive Traction Switch 340 Pivot Steer Switch 341 Truck Hitch In/Out Button .. 341 Ventilation Control Switch. ant Brake Release Hand Valve . 341 Brake Release Hand Pump .... : ce feneeee 342 Material Indicator (Option) 342 Flow Gate Position Indicators. 343 Rear Contral Stations. 3413 Jog Toggle Switch B14 Up/Down Indicators 314 3-Pasition Function Toggle Switch 344 Slope/Grade Controller 345 Mode Switch, 345 Warning Indicator 3-46 Warning Indicator 3-46 LoD . : 346 Up/Down Knob 3-16 Selector Switch. 346 Screed Control Panels 346 LH Control Panel . es : we ceeeeee 37 Extension Slope Toggle Switch 347 LH and RH Flow Gate Control Toggle Switches B47 ‘Auger Override Toggle Switch 3618 Auger Extension Switch 3618 Extension Heater Igniter Switch 348 Extension Fuel Pump Switch 3-48 Main Fuel Pump Power Switch. 3-18 Main Igniter Power Switch 348 PF-161 PaveriFinisher 3TABLE OF CONTENTS TITLE ‘Auger Speed Control Knob... ... Screed Extension In/Out Toggle Switch RH Control Panel a Extension Fuel Pump Switch . Extension Heater Igniter Switch Auger Override Toggle Switch ‘Auger Extension Switch Fuel Pump Switch, Extension Slope Toggle Switch Screed Extension In/Out Toggle Switch Auger Speed Control Knob. Main Igniter Power Switch Main Fuel Pump Power Switch. OPERATING INSTRUCTIONS GENERAL. Pre-Start Checks and Verifications, Starting the Machine, ‘Suggestions to Make Cleanup Easier Positioning the Machine and its Controls Initial Screed Elevation Initial Screed Angle-of- Attack Lighting the Screed Heater. Positioning the Material Truck and Starting to Pave. OPERATING THE MACHINE - GENERAL GUIDELINES . .. MOVING THE MACHINE - UNDER PROPULSION .. MOVING THE MACHINE BETWEEN WORKSITES. ‘Securing the Machine to the Transporter (Tiedown) TOWING THE MACHINE MAINTENANCE INSTRUCTIONS GENERAL. CLEAN UP AND WASHDOWN PERIODIC MAINTENANCE Lubricants LUBRICATION AND SERVICE SCHEDULE Daily Maintenance Requirements. Weekly Maintenance Requirements. Monthly Maintenance Requirements Quarterly Maintenance Requirements ‘Semi-Annual Maintenance Requirements Annual Maintenance Requirements . Miscellaneous Maintenance Tasks. Preventative Maintenance Checklist MAINTENANCE INSTRUCTIONS Daily Maintenance Tasks Front Conveyor Bearing - Grease Rear Conveyor Bearings - Grease Auger Bearings - Grease Screed Vibrator Shaft Bearings - Grease ‘SECTION 3-18 23-19 23-19 23-19 3.20 3.20 3-20 3-20 3-20 3-20 3-20 3-21 23-21 24-10 414 2415 415 446 52 56 513 513 514 515 5-16 5-16 516 S47 S47 518 5-18 519 5-19 5-20 5-20 5-21 521 PF-161 PaveriFinisherTABLE OF CONTENTS TILE SECTION Hydraulic Fluid - Check Level. -5-21 Engine Oil - Check Level +5:23 Engine Radiator - Check Level 15:24 Cooling Fan - Inspect : fee fee 5-26 Truck Hitch Option Rollers - Grease. 5.27 Engine Air Intake Piping - Inspect 5:27 Drive Belts - Inspect 5-28 Fuel Water Separator - Drain 5-28 Crankcase Breather Tube - Inspect 5-28 Conveyor Chains - InspectiAdjust 529 Weekly Maintenance Tasks 531 Truck Hitch Option Slides - Clean/Grease 53 Screed Depth Cranks - Grease : fie fee 5:32 Screed Pivot Points - Grease 5-33 Front Wheel King Pins - Grease 5-34 Front Wheel Bogie Pivot Bearings - Grease. 5-36 Monthly Maintenance Tasks. . 5-35 Parking Brake - Operational Check fee fee 5-38 QUARTERLY MAINTENANCE TASKS 5-38 Engine Oil and Fitter - Change 5-38 Air Cleaner - Check/Change. at ‘Short-Coupled Drive Shaft - Grease. 546 Fuel Pump - Check 546 Raziator Hoses - Check 5-46 Auger/Conveyor Drive Chains - Check/Adjust 5.47 Hopper Hinge Assembly - Inspection/Repair 548 Auger Section - Inspection and Replacement 5.48 SEMI-ANNUAL MAINTENANCE TASKS 5-49 Hydraulic Fluid and Filters - Change 25-49 Draining the Hydraulic System... 5-50 Changing Hydraulic Oil Fiters : 5-53 Removal and Cleaning of Relie (In Hydraulic Tank) te : 5-54 Changing Hydraulic System Charge Filter 5-56 Refiling Hydraulic System with Fluid 557 Engine Coolant = Check 557 ANNUAL MAINTENANCE TASKS, 5-58 Front Bogie Wheels - Repack 5.59 Pump Drive Box - Change Fluid 5-58 Auger/Conveyor Planetaries - Change Fluid 561 Drive Wheel Planetaries - Change Fluid 5-62 Engine Fuel Filter - Change 5-63 Changing a Canister - Type Fuel Fier... 25:63 Changing a Spin-On-Type Fuel Filter. 5-65 Washdown Fuel Fitter - Change. 5-66 MISCELLANEOUS MAINTENANCE TASKS . 567 Adjustment of Hopper Wiper Bars - As Required 5-68 ‘Adjustment of Swing Console - As Required . 5-68 Adjustment of Stecring Consoles and Seats - As Require 5-69 Adjustment of Hopper Side Extensions = As Required 5-70 Drive Tire Servicing and Hydroinflation - As Required 5-70 OFF SEASON STORAGE 5-70 PF-161 PaveriFinisher 5TABLE OF CONTENTS TITLE TROUBLESHOOTING GENERAL. : cee General Fault Isolation Tips/information. How This Section Works. General Troubleshooting Guidelines Alarms Indications and Remedies BLAW KONTROL® ULTRASONIC GRADE CONTROL SYSTEM TROUBLESHOOTING TECHNICAL SPECIFICATION GENERAL. Machine Identification. Environmental Specifications Physical Specifications Miscellaneous Specifications ...........0..5 FUEL AND LUBRICANT SPECIFICATIONS GENERAL. FLUID CAPACITIES HYDRAULIC OIL REQUIREMENTS AND SPECIFICATIONS LUBRICATING OILIGREASE (EXCEPT ENGINE)... . ENGINE LUBRICATING OIL SPECIFICATIONS DIESEL FUEL SPECIFICATIONS . .. HAZARDOUS SUBSTANCE PRECAUTION SCHEMATICS SCHEMATICS. ELECTRICAL SCHEMATIC HYDRAULIC SCHEMATIC. RECOMMENDED SERVICE PARTS INDEX WARRANTY INFORMATION ‘SECTION 62 62 63 6-3 64 66 72 72 72 74 82 83 284 84 86 92 93 o4 PF-161 PaveriFinisherINTRODUCTION PF-161 Paver/FinisherINTRODUCTION INTRODUCTION The purpose of this manual is to provide the operator and site maintenance personnel with knowledge of the fundamental rules and criteria to be followed for the on-site use and maintenance of the Ingersoll-Rand Blaw-Knox PF-161 Paver/Finisher. This instruction manual must be read and fully understood by the operator before operating the machine This manual consists of: + INTRODUCTION + Section 1, SAFETY + Section 2, ASSEMBLY + Section 3, OPERATING CONTROLS AND INSTRUMENTS. + Section 4, OPERATING INSTRUCTIONS + Section 5, MAINTENANCE INSTRUCTIONS + Section 6, TROUBLESHOOTING + Section 7, TECHNICAL SPECIFICATION + Section 8, FUEL AND LUBRICANT SPECIFICATIONS + Section 9, SCHEMATICS + Section 10, RECOMMENDED SPARE PARTS + INDEX Always keep this manual handy for quick reference. If any part of this manual cannot be understood, contact your supervisor or local Ingersoll-Rand Blaw-Knox Distributor. This is an essential condition for working safely with this machine, The correct machine operation, use, and regular maintenance are also essential elements to provide the highest performance and safety. NOTE: This manual is accompanied by an engine instruction manual provided by the engine’s manufacturer. Please follow the operation and maintenance instructions as specified in both the machine and engine manuals. PROCEDURE WHEN RECEIVING THE MACHINE Your machine has been tested, accurately checked, and prepared for shipment. Every part of the machine, including the detached parts, has been accurately checked before being shipped from the factory. When you receive the machine, and before unpacking the equipment, check if damage has ‘occurred during transport and if any parts are missing, ‘Check the equipment by consulting the shipment documents. If goods are damaged or if parts are missing, inform the freight agent as soon as possible They will inform you regarding how to proceed in order to make a complaint and get the damaged or missing goods replaced PF-161 PaveriFinisherINTRODUCTION IDENTIFICATION DATA. ‘An exact description of the model type and serial number of your machine will facilitate fast and efficient response from our parts and service operations. Always provide the model of your machine and its serial number when you contact the local Ingersoll-Rand Blaw-Knox service or parts office. We advise you to record your machine data in the following table to ensure that the paver! finisher and engine information is readily available when you need it. Table 1: Machine Identification Data MACHINE IDENTIFIER IDENTIFYING NUMBER PaveriFinisher Model Number PaveriFinisher Serial Number Year of Manufacture Engine Type Engine Serial Number MACHINE IDENTIFICATION The Ingersoll-Rand Blaw-Knox PF-161 Paver/Finisher identification plate is located at 1, Figure 1 and the engine serial number can be found on its identification plate located at 2, Figure 1 Ui, PF-161 Paver/FinisherINTRODUCTION GENERAL INFORMATION All safety rules in Section 1 must be observed. If further information is required concerning the recommended uses on PF-161 Paver! Finisher, contact your local Ingersoll-Rand Blaw-Knox Distributor. Ingersoll-Rand Company, Road Machinery Division Shippensburg, Pennsylvania 17257 USA Tel: +1- 717-532-9181 (Service and Warranty) Fax: +1 - 717-530-3402 (Service and Warranty) Fax: #1 - 717-530-3403 (Customer Service Parts) Ingersoll-Rand reserves the right to make changes or modifications without prior notice and without incurring any liability to retrofit machines previously shipped from the factory. MACHINE DESCRIPTION The Ingersoll-Rand Blaw-Knox PF-161 Paver/Finisher is a wheel-mounted, mid-sized paver! finisher capable of placing bituminous base, binder and surface course mixes, cement or lime stabilized sub-base and graded aggregate materials. ‘The PF-161 Paver/Finisher functionally consists of two sections (Figure 2). These sections are called the tractor (1, Figure 2) and the screed (2, Figure 2). First, the tractor receives, delivers and spreads the paving material in front of the screed. The tractor then, tows the screed forward over the paving material As the screed is being towed over the paving material it levels, smooths, seals and starts the ‘compaction process on the mat (Newly paved area). PF-161 PaveriFinisherINTRODUCTION The following paragraphs provide a brief description of each of the major components that make up the PF-161 PaverFinisher. Standard components are addressed initially followed by brief descriptions of each of the available options Figure 2 ENGINE The PF-161 Paver/Finishor is powered by the Cummins “Elite” series, EPA certified, 4 cylinder, turbocharged diesel model 4BTA 3.9...239 cubic inch (3.92) displacement, 107 hp (80 kW) @ 2100 rpm. The engine is equipped with an oil cooler, replaceable oil filter, replaceable fuel filter, replaceable air cleaner element and a real-time hour meter located in the electrical junction box. Refer to the Cummins Engine Operation and Maintenance Manual supplied with the Paver! Finisher for additional engine operating and maintenance procedures. ELECTRICAL SYSTEM ‘The PF-161 PaveriFinisher utilizes a 12-Volt, negative ground with a 105-Amp alternator for its electrical needs. Wiring is color coded, number impregnated and the harness is wrapped in polyethylene looms for maximum durability and ease of servicing, All circuits tie to circuit boards located in the operator's swing console and are equipped with automatic reset circuit breakers. PF-161 PaveriFinisherINTRODUCTION HYDRAULIC SYSTEM The PF-161 Paver/Finisher is equipped with a hydraulic system that has a 151-liter (40 gal.) reservoir capacity. Primary filtration is accomplished with 5.0 micron variable depth “Fiberglas” filters on the inlet side of each traction-drive charge pump. ‘Secondary filtration is accomplished with 100-mesh strainers located on the suction side of the general purpose and feeder drive-pump circuits. All hydraulic circuits are routed through a central, easy access valve block equipped with interchangeable solenoid cartridge valves for maximum reliability and easy servicing FUEL SYSTEM The PF-161 Paver/Finisher is equipped with a 144-liter (38 gal.) fuel tank, equipped with a replaceable filter. This fuel tank provides an onboard supply of diesel fuel for the engine, heaters and the pressurized washdown system. COOLING SYSTEM The PF-161 is equipped with a 24.6 L (26 qt.) capacity cooling system. BRAKES ‘The PF-161 Paver/Finisher primary braking is accomplished via the dynamics of a hydrostatic traction drive system Hydraulic secondary parking brakes, an intemal element of the planetary final drive units, can be switch actuated from either operator's console, These spring-applied secondary parking brakes are automatically actuated when the main power switch is in the OFF position, electric power is otherwise interrupted or there is a pressure drop in the general purpose hydraulic system Refer to Section 5 of this manual for additional Brake information. TRACTION DRIVE ‘The PF-161 Paver/Finisher is equipped with an independent, hydrostatic direct drive system with electricihydraulic controlled single-speed planetaries and 2-speed motors. Speed selection is infinitely variable in each of the two speed ranges: Low Range @ 2100 rpm. 0 -3.6 kph (2.2 mph) High Range @ 2100 rpm. 0 - 15.9 kph (9.9 mph) PF-161 PaveriFinisherINTRODUCTION TRACTION LOCK SYSTEM ‘The PF-161 PaveriFinisher is equipped with an electronically controlled hydraulic version of a mechanical-locking differential. This provides a full-time tractive effort at both drive wheels with an intemal pressure modulation feature between right and left-side drives to compensate for the unequal power requirement of turning. PIVOT STEERING An electrical switch on the operator's console hydraulically destrokes the respective right or leftside traction pump to the neutral position for power-assisted steering in confined quarters. REAR SUSPENSION Two 14:00 X 20 low-pressure (182 to 260 kPa (25 to 35 psi), sand rib, high-flotation tires, hydroinflated to 75%. FRONT SUSPENSION Four steerable, 305 mm (12 in, kwide and 559 mm (22 in.}-diameter, solid-rubber tired wheels, are mounted on a offset tandem bogie frame. Front machine weight is proportionally split 40-60% between the front and rear sets of bogies for optimum weight distribution. Tie-rod synchronized steering cylinders (one on each side) are mounted on the outside of the bogie frame for easy service access OPERATOR’S UMBRELLA The PF-161 Paver/Finisher is equipped with an operator's umbrella measuring 1373 mm (54 in.) square. The umbrella comes with mounting hardware included TRUCK HITCH ‘Two bearing-equipped push rollers mounted on an oscillating frame with electricihydraulic actuated roller-equipped clamp arms quickly grip and secure a truck in proper attitude for unloading material into the machines hopper. It automatically compensates for both minor lateral and directional misalignment of the truck with the paverffinisher with no exposed secondary slide mechanisms. Table 2: Truck Hitch Specifications CHARACTERISTIC SPECIFICATION Maximum Arm Opening 3302 mm (130 in.) Minimum Arm Opening 1829 mm (72 in.) Degree of Swivel 28° Drift from Center 305 mm (12 in.) (Automatically self-centering) PF-161 Paver/FinisherINTRODUCTION POWER FLOW GATES Two separately operated, electrically controlled, adjustable flow gates (2, Figure 3) meter material delivery to the augers. The gates are located in the conveyor tunnel entry at the rear hopper. DUAL FEED SYSTEMS Separate, infinitely variable speed, hydrostatic planetary drive for right and left-side feed systems provide optimum auger/conveyor operation throughout the machine's entire capability range. Right and left-side systems function independently and operation is. controlled either manually with electrical switches or automatically by electrical sensing elements positioned at the outer end of each auger. Manual electrical switches are positioned ‘on the tractor operator's swing console and on the screed control consoles. Maintenance-free auger/conveyor bearings combine an exclusive patented seal with a new synthetic hydrocarbon lubricant to eliminate the daily greasing requirement, PF-161 PaveriFinisherINTRODUCTION CONVEYORS Conveyor assemblies (1, Figure 3) consist of solid bars riveted to special, heat-treated steel, offset link R2 (rapid -repair), heavy-bushed roller chain riding on forged steel sprockets Conveyor floor plates and rear wrap plates are constructed of abrasion-resistant QT steel with a Brinell hardness range of 360 to 440 throughout the entire plate thickness. Conveyor Tunnel Opening 1362 mm (63.625 in.) Conveyor Floor Plate Thickness. 10 mm (375 in.) AUGERS: ‘Augers (1, Figure 4) consists of replaceable, high alloy, cast steel hemi-screw sections. ‘Augers are adjustable in height hydraulically by simply actuating an electrical switch Table 3: Auger Specifications CHARACTERISTIC ] ‘SPECIFICATION ‘Auger Diameter 356 mm (14 in.) ‘Auger Flight Thickness 16 mm (5/8-in.) ‘Auger Height Adjustment (above grade) | 114-279 mm (4.5 - 10.5 in.) Figure 4 PF-161 Paver/FinisherINTRODUCTION AUTOMATIC FEED CONTROL SYSTEM The PF-161 Paver/Finisher is equipped with a Mat Kontrol® II to control the operating speed of the dual feed systems. This system is supplied with a choice of either Paddle Sensors or Ultra 3°° (Ultrasonic Sensing System) Sensors. The following paragraphs provide a brief explanation of each sensor system MAT KONTROL® II WITH PADDLE SENSORS An electric/hydraulic control arrangement that automatically controls both the on-off action and infinitely variable operating speed of the dual feed systems. Paddle Sensors are mounted at the outer end of each auger. From these locations, they monitor the volume of material in front of the screed via actual contact with the material. As these paddles detect the level of material present, they will actuate the feeder drives as necessary and either cause an increase or decrease of conveyor speed or even start and stop the conveyor(s), as appropriate, to maintain a consistent volume of material to the screed, MAT KONTROL® Il WITH ULTRA 3°® SENSORS An electric/hydraulic control arrangement that automatically controls both the on-off action and infinitely variable operating speed of the dual feed systems. The Ultra 3s® sensors are positioned at the outer end of each auger. From these positions, they monitor the volume of material in front of the screed and control the feeder drives, as necessary, to maintain a consistent volume of material to the screed. Unlike the paddle system described above, the Ultra 3°° system makes no actual physical contact with the material. Instead, it works very similar to an active sonar system, as it sends sound pulses to the material in front of the screed and waits for a bounce-back or echo. Accurate measurement of the resulting time delay between output pulse and the returning echo results in a level of accuracy rivaling mechanical means such as paddles. This system is much less vulnerable to heat and abrasions than the paddle system since it has no physical contact with the material. SMOKE-EATER® VENTILATION CONTROL SYSTEM This is a machine-mounted heat and fume extraction system that provides a cleaner, cooler and more environmentally friendly work area for the machine's operator and screedman. The system is provided standard on all machines manufactured for domestic use. The system consists of a single, hydraulically-driven, high-volume fan and two collector hoods, The system gathers heat and fumes from the paver's auger and screed area and disperses them into the atmosphere away from the operators via a single, deck-mounted exhaust stack The exhaust stack folds down to minimize transport height of the machine. A 3:position switch controls the system. The three positions of this switch are; “ON” (constant system operation), “AUTO” (system operates only when the paver is in motion), and “OFF” (the system does not operate) ‘vacuum sight switch is incorporated into the fan intake plenum to permit visual monitoring of the system for proper operation PF-161 PaveriFinisherINTRODUCTION WASHDOWN SYSTEM A pressurized diesel fuel washdown system with a 10.7 m (35 ft.) hose and spray valve nozzle (2, Figure 5) is mounted on a self-storing, spring-retracting hose reel. Pressurization of the washdown hose is controlled via a washdown hose pump switch (1, Figure 5). Figure 5 CONTROLS The dual control stations (right and left side) are each equipped with an operator's seat (2, Figure 6) and a direction/speed control pedestal (1, Figure 6). ‘A.common, center-mounted, swing console (3, Figure 6) with position lock, provides both control stations with electrical switch control of the main power, starter, throttle, horn, shifting of traction-drive motors, right and left-side feed system function, screed lift, auger lft, folding hopper, flow gates, screed vibrator function, parking brake, traction lock system, pivot steering, optional truck hitch and optional front-wheel power assist. The screed vibrator frequency/amplitude, feed system speed, flow gate override, powered screed functions and mat depth are all controlled from the screed control boxes (4, Figure 6). The swing console also contains the tachometer/hour meter and analog gauges for engine oil pressure, water temperature, voltmeter and hydraulic oil temperature. Warning lights are also included for "Brake On", “Change Hydraulic Filter" and “Low Material" for units equipped with optional material indicators. PF-161 Paver/Finisher "2 INTRODUCTION Refer to the Section 3, OPERATING CONTROLS AND INSTRUMENTS of this manual for a ‘complete description of the Operator's Consoles, Controls and Instruments. Figure 6 SCREED CHOICES/SCREED OPTIONS The following paragraphs briefly describe the various screed choices and screed options that ‘may be on your machine, SCREED HEATERS Al Blaw-Knox screeds offer screed heating options. Your machine will contain one of the following screed heater systems. DIESEL ONLY HEATERS These heaters are unitized, diesel-fueled, SureFire® bumer/blowers. Each unit contains a ‘manual switch-activated spark igniter. A built-in timer controls the fuel pump which supplies diesel fuel to the screed heaters and the washdown system to provide an infinitely variable 15-30 minute run cycle time. Run cycle time is limited in this way to protect the pump from accidental extended operational misuse which could result in premature pump failure. PF-161 PaveriFinisherINTRODUCTION DIESEL HEATERS WITH AUTOMATIC TEMPERATURE AND IGNITION CONTROL (ATIC) These heaters are unitized, diesel-fueled, SureFire® bumer/blowers. Each unit is equipped with Automatic Temperature and Ignition Control (ATIC). This ATIC system automatically ignites the heaters to preheat and maintain the temperature of the screed plate within 8° C (14° F) range of any preselected temperature within the system’s operating range capability of 80° to 177° C (175° to 350° F), The ATIC system incorporates flame failure and high- temperature shutdown safety features. PROPANE (LPG) HEATERS WITH ATIC These heaters are unitized, diesel-fueled, SureFire® burner/blowers. Each unit is equipped with Automatic Temperature and Ignition Control (ATIC). This ATIC system automatically ignites the heaters to preheat and maintain the temperature of the screed plate within 8° C (14° F) range of any preselected temperature within the system's operating range capability of 60° to 160° C (125° to 320° F). The ATIC system incorporates flame failure and high- temperature shutdown safety features. This option includes a propane bottle mount, pressure regulator valve and connector tubing. This option does not include the propane bottle itself. WEDGE-LOCK® SCREED ‘The Wedge-Lock® Screed is a basic 2.44 m (8 ft.) fixed width, vibratory screed. The screed contains a one-piece 623 mm (24.5 in.) wide x 13 mm (0.5 in.) thick, bolt-on replaceable, abrasion-resistant, alloy-steel screed plate. The screed also comes equipped with spring- loaded MatStop® edger plates with replaceable wear shoes, edger guides and cut-off plates. Bevel edger plates are optional Accenter crown kit is available with the Wedge-Lock® Screed. This mechanical, dual crown kit provides simultaneous adjustment of center lead and tail crown from 76 mm (3 in.) positive to 19 mm (3/4 in) negative Below is a list of the Wedge-Lock® Screed specifications. Table 4: Wedge-Lock® Screed Specifications CHARACTERISTIC SPECIFICATION ‘Standard Paving Range (with cut-off plates) | 1.83-2.44m (6-8 ft.) Maximum Paving Width 5.79 m (19 ft.) Paving Depth Range 6 - 203 mm (0.25 - 8 in.) Optional to 305 mm (12 in.) Vibrator Speed (0 - 3100 vpm (52 Hz) PF-161 Paver/Finisher 13INTRODUCTION WEDGE-LOCK® SCREED EXTENSIONS Wedge-Lock® screed extensions are used to increase paving width. These extensions to the basic screed are available in 152 mm (6 in.), 305 mm (12 in.), 610 mm (24 in.) and 914 mm (36 in.) lengths. They may be supplied either in kit form or individually. Various options correspond to specific extension sizes. Table 5 below provides a list of these extensions and the features available for each. Table 5: Wedge-Lock® Screed Extensions Size and Options Available Options Size - Vibration | Heat cone caet 152 mm (6 in.) 305 mm (12 in.) x 610 mm (24 in.) xx (914 mm (36 in.) x x 2.5/5B HYDRAULIC SCREED EXTENSIONS Optional, hydraulic telescoping extensions with replaceable screed plates mount on either a basic or extended Wedge-Lock® Screed to permit increased paving width of up to 762 mm (2.5 ft) on either or both sides of the screed, while continuing to pave Slope control on each extension is accomplished manually up to a maximum 25 mm (1 in) in 305 mm (12 in.) positive in any extended width up to 25 mm (1 in.) in 305 mm (12 in.) negative fully extended. An additional 305 mm (12 in.) modular extension can be installed on the outer end of either or both 2.5/5B extensions to increase paving width up to a maximum of 4.57 m (15 tt), POWER SLOPE OPTION FOR 2.5/5B HYDRAULIC EXTENSIONS This is an electrically actuated power sloping arrangement with visual sight gauges which replaces the standard mechanical sloping mechanism. This option provides for effortless on-the-go slope control of each extension relative to the main screed up to 25 mm (1 in.) in 305 mm (12 in.) positive at any extended width and up to 25 mm (1 in.) in 305 mm (12 in.) negative fully-extended, Slope control switches are located on the screed control consoles. PF-161 PaveriFinisherINTRODUCTION BERM ATTACHMENT OPTION FOR 2.5/5B HYDRAULIC EXTENSIONS This option replaces the standard screed plate arrangement to provide up to 102 mm (4 in.) of vertical rise in 610 mm (24 in.) at the outer edge of each extension. The addition of this option provides the means to form water drainage channels up to 610 mm (24 in.) in from the edge of the mat, reducing the need for curbing OMNISCREED® 1A This is a basic 2.44 m (8 ft.) power extendible, vibratory screed providing infinitely variable on- the-go-paving width flexibility with uniform compaction and surface texture across the entire mat width. The main screed and both independent, front-mounted, hydraulically extendible sections are equipped with vibrators and bolt-on replaceable, abrasion resistant QT Stee! screed plates, These plates are 457 mm (18 in.) wide on the main screed and 356 mm (14 in.) wide on the extendible sections. All plates are 13 mm (0.5 in.) thick, Spring-loaded MatStop' ‘edger plates with replaceable wear shoes, edger guides and cut-off plates are included. Bevel ‘edger plates are optional. Below are the specification details for the OmniScreed® IA Table 6: OMNISCREED® Specifications CHARACTERISTIC SPECIFICATION REMARKS Standard Paving Width 1.83-4.0m(6-13.51t) | With cut-off plates ® Maximum Paving Width 5.23 m (17 ft, 2in.) With optional Wedge-Lock’ extensions Paving Depth Range 6 - 203 mm (0.25 - 8.00 in.) | Optional to 305 mm (12 in.) Vibrator Speed 0 - 2500 vpm (42 Hz) Choice of either mechanical or hydraulic-powered dual ‘crown kits to simultaneously adjust center lead and tail 76 mm (3 in.) positive - 19 Center Crown mm (0.75 in.) negative crown Extension Power Slope 25mm (1 in.)in 305mm —_| For any extended width Range (12 in.) positive (Oto 8%) Diesel or propane-fueled ‘SureFire® bumer blowers. Each unit contains an individual switch-activated ingniter and provides fast even heat over the entire screed base regardless of the extendible section position. 2main burners and 1 on Heat each extendible section PF-161 Paver/Finisher 1816 INTRODUCTION GENERAL EQUIPMENT OPTIONS The following paragraphs provide brief explanation of the general options that are available and may be present on your PF-161 PaveriFinisher. These options do not fall under any particular category as did the screed options discussed earlier. Front Wheel Power Assist Option This is a separate, constant torque, hydrostatic-drive arrangement for the rear set of front bogie wheels. It provides up to 20% more tractive effort in the machine's paving speed range. Material Indicator Kit Option This kit consists of electrical sensing elements that when mounted on the flow gates audibly warn the paverifinisher operator when material level drops below a preset level at the conveyor tunnel entry. Blaw-Kontroll® Il Option This option is an extremely accurate, electronic grade-and-slope control system. It automatically maintains the elevation and transverse (side-to-side) slope of a paver/finisher’s screed to preset specification parameters, with respect to a single reference. This is accomplished by controlling the machine's hydraulic system. ‘The system can also be set up to control the elevation of each side of the screed with respect to grade by referencing from both sides of the paver/finisher simultaneously. The system will sense and correct for deviation in grade elevation as small as 0.127 mm (0.005 in.) when using the standard Blaw-Knox mechanical-grade sensor. Slope resolution is 0.005%. PF-161 PaveriFinisherINTRODUCTION UltraEye® V Grade Sensor Option This option is an ultrasonic “non-contacting” grade sensor for the Blaw-Kontro!® II system. This option is directly interchangeable with the standard mechanical-grade sensor. This sensor provides a resolution of 0.508 mm (0.020 in.) Automatic Level Control (Also Known as a Joint Matcher) Op! This is an electric/hydraulic control system that automatically controls the elevation of the mat being placed on one side of the paverifinisher with respect to a reference surface such as an adjacent mat or curb, This option is also available in sets (2 each) to control mat elevation on both sides of the machine simultaneously. The resolution of this system is 3.175 mm (0.1259 in). Floating Beam Reference Option This option is used as a sensing reference for a Blaw-Kontro!® II Control System. It accurately averages longitudinal irregularities in the grade over which paving is being performed. This eliminates the expense of installing and maintaining stringline references. It is available in 6.10 m (20 ft), 9.14 m (30 ft) and 12.20 m (40 ft) lengths and in sets (2 each) for dual grade referencing Mat Reference Option This is a 6.10 m (20 ft) rear-mounted aluminum beam riding on eight (8) sets of spring-loaded dual road wheels with the aluminum bridge and hardware required to match it to a 9.14 m (30 ft. front-mounted floating beam. This produces a 16.77 m (55 ft.) mobile-grade referencing system Additional Operator’s Umbrella Option This is a 1372 mm (54 in.) square umbrella with mounting hardware supplemental to the standard single unit to accommodate the second operator's control station. PF-161 Paver/Finisher 7INTRODUCTION IDENTIFICATION OF MAJOR COMPONENTS Legend: 1. Hopper 6. 2. Conveyor 7. 3. Flow Gates 8 4. Direction/Speed Lever Control Pedestal 9, 5. Main Console 10. Seat Screed Screed Tow Point Front Wheel Bogies Rollers PF-161 PaveriFinisherSECTION 1 - SAFETY PF-161 Paver/FinisherSection 1 SAFETY SAFETY BE AWARE OF SAFETY INFORMATION This is the 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 with the safety-alert symbol Signal words are categorized and used in a strict hierarchy of seriousness, depending on the nature of the hazard and whether or not itis life threatening to personnel, injurious to personnel or potentially damaging to property, equipment or could have an adverse effect on the machines ability to perform in an efficient manner. DANGER, WARNING, or CAUTION safety labels may be located near specific hazards, and are also used in this manual to alert the reader to specific hazards - as defined below. T alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER is used to indicate the presence of a yyy G hazard which will cause severe personal injury or death if the warning is ignored. is the SAFETY ALERT SYMBOL. It is used to (Red Background) WARNING is used to indicate the presence of a hazard which can cause severe injury or death if the warning is ignored. (Orange Background) CAUTION is used to indicate the presence of a hazard which will or can cause personal injury, or property damage if the warning . (Yellow Background) NOTICE is used to notify people of i i NCO) (01 SIMI operation, crmairtonance information which fs important but not hazard related. (Blue Background) PF-161 Paver/FinisherSAFETY Section 1 OVERVIEW Before you operate, maintain, or in any other way use this Paver/Finisher: READ and STUDY this manual. KNOW how to safely use the paverffinisher's controls and what you must do for safe maintenance. ALWAYS wear or use proper personal protective equipment required for your personal protection. Ifyou have ANY QUESTIONS about the safe use or maintenance of this paverifinisher, ASK YOUR SUPERVISOR OR CONTACT ANY INGERSOL-RAND DISTRIBUTOR. NEVER GUESS-ALWAYS CHECK! WARNINGS The following conventions are used in this manual to designate instructions of particular importance. NOTE: Refers to special information on the efficient use of the machine. NOTICE: Denotes special nonhazardous related information, CAUTION: Refers to orders and prohibitions directed towards preventing product/property damage and/or degraded machine performance WARNING: Refers to orders and prohibitions designed to prevent personal injury and/or death, GENERAL Ingersoll-Rand cannot foresee all possible circumstances that might lead up to a potential hazard. Therefore, the combination of warnings listed in this manual and those placed on the machine itself are not intended to be all inclusive. Operators and maintenance personnel must be alert to recognize and avoid potential hazards. They should also have comprehensive training, required skills and necessary tools to properly perform their functions, The machine was built in accordance with state-of-the-art standards and recognized safety rules, Nevertheless, its misuse or careless operation may constitute a life-threatening risk to the user or to third parties and may cause damage to the machine or other material property. ‘The machine must be used only as described in the operating and control sections of this manual. The machine must only be operated by safety-conscious persons who have been properly trained in operating the machine and are fully aware of the safety issues associated with its operation, Any functional disorders, especially those affecting the safety of the machine, must be corrected immediately. PF-161 Paver/Finisher 13Section 1 SAFETY The machine is designed exclusively for the Pave/Finish of asphaltic road construction materials. Use of the machine for purposes other than that mentioned, such as towing other vehicles/equipment is considered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user. Operating the machine within the limits of its designated use also involves compliance with the inspection and maintenance directives contained in the operating section of this manual. SELECTION AND QUALIFICATION OF PERSONNEL Work on and with the machine must be performed by qualified personnel only. Statutory minimum age limits must be observed. Individual responsibilities of the personnel responsible for operation, setup, maintenance and repair of the machine should be stated clearly Define the machine operator's responsibilities: not only pertaining to the machine's operation, but also with regard to observing traffic regulations. The operator should have the authority to refuse instructions by third parties that are contrary to safety. Do not allow persons being trained or instructed in the operation or maintenance of the machine to work without permanent supervision by an experienced person. Work on the electrical system and equipment of the machine must be done only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and must be in accordance with electrical engineering rules and regulations. Work on the chassis, brake, hydraulic and steering systems must be performed by skilled personnel with special knowledge and training for such work ORGANIZATIONAL MEASURES Operation and Maintenance manuals MUST always be available at the site where the machine is used OBSERVE AND INSTRUCT the user in all other generally applicable legal and mandatory regulations relevant to accident prevention and environmental protection. These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment, and traffic regulations. ‘SUPPLEMENT operating instructions with detailed working instructions pertaining to the specific work location. ALWAYS be sure that persons entrusted with work on the machine have read the operating instructions and, in particular, the chapter on safety before beginning work, Reading the instructions after work has begun is too late. This is especially important for persons who work only occasionally on the machine, e.g. during set up or maintenance. MAKE CERTAIN personnel are working in compliance with the operating instructions and are alert to risks and safety factors. PF-161 Paver/FinisherSAFETY Section 1 ALWAYS tie back or otherwise secure long hair, wear close-fitting garments and avoid wearing jewelry such as rings, bracelets and necklaces. Injury may result from clothing, hair, or jewelry being caught up in the machinery USE protective equipment wherever required by the circumstances or by law. OBSERVE all safety instructions and warnings attached to the machine and in this manual. BE SURE all safety instructions and warnings attached to the machine are complete and perfectly legible. STOP the machine immediately in the event of any maifunction. REPORT the malfunction to the proper authority/person. The continued operation of a machine that is not working properly may cause extensive damage to the machine or significantly increase the hazards to operating personnel fram abnormal operating conditions. NEVER provide service or maintenance to the machine in ANY manner other than that which is described in this manual, NEVER make any modifications, additions or conversions to the machine which might affect safety without the manufacturer's approval. This applies to the installation and adjustment of safety devices and valves as well as to welding work on load bearing elements. ALWAYS ADHERE to prescribed intervals or those specified in the operating instructions for routine checks and inspections. Consistently performing scheduled maintenance will extend the life of your machine. MANDATORY SAFETY MEASURES Never clean, lubricate or service the paverifinisher when it is running Always operate the SmokEater® Ventilation Control System when placing paving materials which produce fumes. Do not operate the machinery while under the influence of drugs or alcohol. Use safety items (hard hat, safety boots, eye and ear protection, etc.) as appropriate or required. Do not wear radio or music headphones while operating the machines. Do not wear jewelry while operating the machine, Re-install safeguards and shields securely and clear all maintenance tools before starting the engine after maintenance. Ifyou have ANY QUESTIONS about the safe use or maintenance of this machine, ASK YOUR SUPERVISOR OR CONTACT ANY INGERSOLL-RAND BLAW-KNOX DISTRIBUTOR, NEVER GUESS-ALWAYS CHECK! Failure to adhere to these instructions may result in serious injury or even death PF-161 Paver/Finisher 1516 Section 1 SAFETY LOADING AND UNLOADING Loading Dock with Ramp (Preferred Method) The easiest and safest method for unloading your Ingersoll-Rand Blaw-Knox PF-161 from a truck is to drive it off onto a loading dock that is level with the truck bed. Before unloading: + Remove any loose parts from the truck deck or machine. + Release and remove any tie-down equipment, and chooks and blocks under the machine frame. + Position the rear of the trailer firmly against the loading dock. + Engage the truck's parking brake, Alternate Ramp Method Ifa loading dock is not available, a ramp or set of ramps positioned at a 12° angle may be used, Ramp(s) must be rated to support the weight of the machine, 18T (20 tons). + Remove any loose parts from the truck deck or machine. + Release and remove any tie-down equipment, and chooks and blocks under the machine frame PRE-START INSPECTION INSPECT your paver/finisher daily. Ensure that the routine maintenance and lubrication are being dutifully performed. Have any malfunctioning, broken, or missing parts repaired or replaced before use. Refer to the Maintenance Schedule located in Section 5 of this manual. VERIFY that all instruction and safety labels are in place and readable. These instructions are as important as any other equipment on the paver/finisher. Refer to the decal location drawing later in this Section. BE MINDFUL of your surroundings before fueling. NEVER fill the fuel tank with the engine running, while the machine is located near an open flame or while operating personnel are smoking. Smoking is PROHIBITED within 15 M (50 FT.) of the machine while fueling. ALWAYS wipe up any spilled fuel. CHECK the Front Wheel assist relief pressure. It should be set according to the operating surface. CHECK for any maintenance and repair WARNING tags placed on the machine. DO NOT operate the paver/finisher until repairs have been made and the WARNING tags have been removed by authorized personnel. KEEP the operator's platform CLEAN. REMOVE any dirt, debris or foreign material from the operator's platform to reduce the danger of slipping, KNOW the location of the Emergency Shut-Down Control PF-161 Paver/FinisherSAFETY Section 1 ALWAYS know the capabilities and limitations of your equipment in terms of speed, gradeability, steering and braking, BE AWARE of the dimensions of your paverffinisher-height and weight-as well as your screed extension’s dimensions and weight or height and dimensions of the operator's umbrella. CHECK for any operating conditions that could be dangerous such as holes, banks, underground culverts, manhole covers, water melt pits, curbs and/or street boxes. CHECK the Parking Brake on flat open ground. Low speed range (Low Motor Shift Switch position) should not overpower the brake. If the Parking Brake can be overpowered, brake packs inside of the final drive planetaries must be repaired. Parking Brake is not adjustable. SAFETY INSTRUCTIONS GOVERNING OPERATION AVOID any operational mode or procedure that might sacrifice safety TAKE all necessary precautions to ensure that the machine is used only when in a safe and reliable condition OPERATE the machine only if all protective and safety oriented devices, such as removable safety devices, emergency shut off equipment, soundproofing elements and exhausts, are in place and fully functional. CHECK the seat belt regularly for wear or damage. Inspect the belt hardware and fabric. Replace if the hardware is damaged or strap is nicked, frayed or loose stitching is found. START the machine from the driver's seat only and FASTEN the seat belt before starting the engine. WATCH the indicators during start up and shutdown procedures in accordance with the operating instructions. Refer to the lamplindicator light check procedures in the Section 5 of this manual CHECK the surrounding area for pedestrians, MAKE SURE no one is at danger or risk before starting up or setting the machine in motion. CHECK that braking, steering, signalling and lighting systems are fully functional before starting work or traveling with the machine. CHECK that accessories have been safely stowed away before setting the machine in motion. OBSERVE the valid traffic regulations when traveling on public roads. ALWAYS MAKE SURE the machine is in a condition compatible with these regulations. ALWAYS SWITCH ON the lighting system in conditions of poor visibility and after dark. MAKE SURE there is sufficient clearance when crossing underpasses, bridges and tunnels or when passing under overhead lines. PF-161 Paver/Finisher 17Section 1 SAFETY ALWAYS KEEP at a safe distance from the edges of building pits and slopes. AVOID any operation that might be a risk to machine stability ALWAYS SECURE the machine against inadvertent movement and unauthorized use before leaving the driver's seat. NEVER SHIFT the transmission on a grade without first stopping the machine and applying the parking brake Starting ALWAYS USE hand rails and steps to get on and off the Paver/Finisher. ALWAYS MAINTAIN a “three-point contact” when climbing onto or off of a Paver/Finisher, READ and FOLLOW ALL instruction decals. ALWAYS be seated with the seat belt on when operating the machine. BEFORE attempting to start the engine, ENSURE that the Direction-Speed lever is in the NEUTRAL position. ‘START the engine from the operator's position only NEVER jump start the machine directly to the starter or starter solenoid. SEVERE INJURY or even DEATH could result from the machine lurching forward or reverse and running over the person(s) attempting to jump start the machine. AVOID personal INJURIES by making sure that the machine being jumped does not touch or come in contact with the machine supplying the jump. NEVER jump a frozen battery, it will EXPLODE. While charging lead acid batteries generate explosive gases. Keep SPARKS, FLAMES and lighted SMOKING material AWAY from BATTERIES. ALWAYS wear safety glasses when working near batteries. Proceed as follows when jump starting the machine: + Connect the Positive (+) ten the discharged battery. jinal of the booster battery to the Posi e (+) terminal of + Connect the Negative (-) terminal of the booster battery to the best ground point on the machine away from the battery. + Follow all the recommended engine starting procedures. + Remove the jumper cables in the reverse order of their connection as soon as the engine has started. 18 PF-161 PaveriFinisherSAFETY Section 1 Operating ALWAYS make sure that no person or obstruction is in your line of travel before starting to move the PAVERIFINISHER machine, ALWAYS LOOK in all directions BEFORE changing your direction in travel, NEVER CLIMB onto or off of the mac! eat any time while it is operating/running ALWAYS remain seated with your seat belt on when operating the paverifinisher, NO EXCEPTIONS. ALWAYS USE EXTREME CAUTION and be very observant when operating in close quarters or congested areas KNOW and USE the hand signals required for particular jobs and know who has the responsibility for signaling, NO RIDERS. NEVER carry passengers. NEVER allow anyone to stand within the paverifinisher “articulation area” with the engine running. KNOW the area in which you are working. Familiarize yourself with work site obstructions and any other potential hazards in the area. When the SmokEater® Ventilation Control System exhaust stack is installed, never attempt to pass under low overhead obstructions, such as bridges or utility wires, without first confirming there is adequate clearance. Always lower or remove the exhaust stack if there is any question about clearance. READ and FOLLOW ALL instruction decals. Stopping ALWAYS park the paverfinisher on solid level ground. If that is not practical, park the paver! finisher at a right-angle to the slope and chock the wheels. Reduce the travel speed by moving the Direction Speed Levers before stopping the machine. To stop the machine, push the Direction-Speed Lever back to NEUTRAL. Push the Main Switch OFF. The parking brake will automatically engage. Before leaving the operator's seat, ALWAYS BE SURE that all control switches are in the OFF ‘or NEUTRAL position and the engine is shut off. Before leaving the operator's seat MAKE CERTAIN that the hopper wings are lowered and the screed is lowered or secured in the raised position. ALWAYS mount and dismount the machine from the rear using the walkways, steps and handrails provided, Never jump from the operators platform to the ground, ALWAYS maintain a “three-point contact” when climbing onto or off of the paverifinisher. USE proper flags, barriers and warning devices to warn others of your presence, especially when parking in heavy traffic. PF-161 Paver/Finisher 19Section 1 SAFETY Maintenance In any work concerning the operation, conversion or adjustment of the machine and its safety oriented devices or any work related to maintenance, inspection and repair, always observe the start up and shutdown procedures set aut in the operating instructions and the information ‘on maintenance work ENSURE that the maintenance area is adequately secured as outlined below. If the paverifinisher is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by: + locking the principle control elements and removing the ignition key and/or + rotating the battery master switch to “OFF” and attaching a warning sign to the battery master switch. Before starting any work, check the de-energized parts for the presence of power and ground or short circuit any parts found to contain residual power in addition to insulating adjacent live parts and elements. ‘The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately. CARRY OUT maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movement. ALWAYS USE the correct tools and workshop equipment when performing maintenance to the machine, KEEP all standing surfaces free from mud, dirt, snow and ice. CLEAN the machine, at the end of each workday while the machine is still warm with diesel fuel, kerosene or other appropriate (biodegradable) cleaning solution All residual asphalt materials should be removed from the paver, especially in the material handling areas and the surfaces sprayed to eliminate any remaining residue. This leaves a petroleum film on surfaces to reduce the potential for material sticking the next time the paver is used. SPECIAL CARE MUST BE TAKEN with the engine and battery area so that cables. and/or hoses are not damaged or disconnected. After cleaning, EXAMINE all fuel and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. REPAIR or REPLACE defective parts immediately ALWAYS TIGHTEN any screwed connections that have been loosened during maintenance and repair. ENSURE that all consumables and replaced parts are disposed of safely and with minimum environmental impact. Any safety devices removed during setup, maintenance or repair purpose MUST BE refitted and CHECKED immediately upon completion of the maintenance and repair AVOID, whenever possible, servicing, cleaning, or examining the paverffinisher with the engine running AVOID, whenever possible, servicing or providing maintenance unless the machine is. adequately secured against movement. PF-161 PaveriFinisherSAFETY Section 1 NEVER fillthe fuel tank with the engine running. Do not permit sparks, open flames or smoking within 15 M (50 ft) of the machine while refueling. Never refuel the machine with the screed heaters operating. ALWAYS wipe up any spilled fuel. DO NOT alter the engine's governor settings from those indicated in the engine manual and the engine option plate. ALWAYS replace damaged or lost decals. It is dangerous to operate the machine without these decals. Refer to the parts manual for the proper location and part number for all decals. In order to ENSURE the SAFE OPERATION, optimum performance and to PROTECT your WARRANTY, use only genuine Ingersoll-Rand replacement parts. DISCONNECT the battery cables when working on the electrical system or when welding on the machine, BE SURE the battery area is well ventilated (clear of fumes) should it be necessary to connect ‘a jump battery or battery charger. Fumes from the battery can ignite by a spark and explode BE SURE the battery charger is “Off” when making the connections if battery charging is. required. The electrical equipment of machines is to be INSPECTED and CHECKED at regular intervals. Defects such as loose connections or scorched cables MUST BE RECTIFIED IMMEDIATELY Welding, flame cutting and grinding work on the machine SHOULD ONLY BE DONE if expressly authorized, as there may be a risk of explosion and fire, Before beginning welding, flame cutting and grinding operations, clean the machine and its surroundings from dust and other flammable substances and make sure that the premises are adequately ventilated (risk of explosion). Hydraulic hose assemblies must be visually inspected at regular intervals and immediately replaced if they show signs of chafing, cracking brittleness, deformation, blistering, leakage, fitting separation, corrosion or other damages which may affect their function and strength, Do not work on hydraulic lines while the engine is running and the system is under pressure. The hydraulic fluid remains under pressure long after the engine has been stopped. Do not, work on any hydraulic hose or fitting unti the pressure has been relieved correctly Hot hydraulic fluid will cause severe burns. Wait for fluid to cool down before disconnecting lines. NEVER USE YOUR HANDS to check for hydraulic leaks when inspecting a hydraulic system. Use a piece of cardboard an always wear gloves and eye protection Fluid penetration from a pin hole leak can cause severe injury or death, Get immediate treatment if fluid has been injected under your skin. DEPRESSURIZE ALL SYSTEM SECTIONS and pressure pipes (hydraulic system, compressed air system) to be removed in accordance with the specific instructions for the unit concemed before carrying out any repair work. Hydraulic lines MUST BE laid ang fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements. PF-161 Paver/FinisherSection 1 SAFETY When handling oil, grease and other chemical substances, OBSERVE the product related safety regulations. ENSURE that all consumable and replaced parts are disposed of safely and within environmental regulations. Work on the electrical system and equipment of the machine must be done only by a skilled electrician or by instructed person under the supervision and guidance of a skilled electrician and must be in accordance with electrical engineering rules and regulations. If provided for in the regulations, the power supply must be cut off to parts of machines, on which inspection, maintenance and repair work is to be carried out Be careful when handling hot consumables (risk of burning or scalding), and wear the appropriate personal protective equipment. HAZARDOUS SUBSTANCE PRECAUTION The following information is provided to assist the owners and operators of Ingersoll-Rand Blaw-Knox machinery. Further information may be obtained by contacting your Ingersoll-Rand Blaw-Knox Road Machinery Equipment Distributor. ‘The following substances are used in the manufacture or produced during the operation of this machine and may be hazardous to health if used incorrectly. SUBSTANCE PRECAUTION Hydraulic Oil ‘Avoid ingestion, skin contact and breathing fumes. Engine Lubricating Oi| —_| Avoid ingestion, skin contact and breathing fumes. Engine Fuel Avoid ingestion, skin contact and breathing fumes. AntiFreeze Avoid ingestion, skin contact and breathing fumes. Rust Preventative Avoid ingestion, skin contact and breathing fumes. Electric Motor Dust (Brushes/Insulation) Avoid breathing dust during maintenance. Battery Electrolyte ‘Avoid ingestion, skin contact and breathing fumes. Avoid breathing Engine Exhaust Fumes Avoid buildup of fumes in confined spaces. Paving Mixtures ‘Avoid ingestion, skin contact and breathing fumes. Preservative Grease ‘Avoid ingestion, skin contact and breathing fumes. SAE Gear Oil Avoid ingestion, skin contact and breathing fumes. PF-161 PaveriFinisher