Fayat Bomag CR 820 T Tier 4 Operating Instructions, Maintenance Instructions
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Fayat Bomag CR 820 T Tier 4 Operating Instructions, Maintenance Instructions

Hot mix asphalt paver
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Operating Instructions
Maintenance Instructions
CR 820 T Tier 4
Hot Mix Asphalt Paver
00808924
05/20

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  • Page 1 Operating Instructions Maintenance Instructions CR 820 T Tier 4 Hot Mix Asphalt Paver 00808924 05/20...
  • Page 2 Intentionally Left Blank...
  • Page 3 Table of Contents TABLE OF CONTENTS Operations Manual Date May 2020 CR 820 T Page 1...

  • Page 4: Table Of Contents

    Table of Contents Table of Contents 1 INTRODUCTION ....................1-1 Notes to the Operations Manual ................1-2 Safety Information ..................... 1-2 Safety Alert Symbol ....................1-2 Safety Notes ...................... 1-2 California 65 Warnings ..................1-2 USA Federal Clean Air Act ..................1-3 Customer Assistance ...................
  • Page 5 Table of Contents Operation of Control Interlocks ................. 2-19 General ........................2-19 Lifting Precautions ..................... 2-19 Crushing or Cutting Prevention ................ 2-19 Safe Paver Operation ..................2-20 Equipment and Tools ..................2-20 Fire or Explosion Prevention ................2-20 Questions ......................2-21 3 TECHNICAL DATA ....................3-1 Dimensions ........................
  • Page 6 Table of Contents Left of Center Gauge Cluster ................ 4-20 Right of Center Gauge Cluster ..............4-20 Center Gauge Cluster ..................4-20 Lower Screen Area ..................4-20 Left Side Button Icons .................. 4-20 Right Side Button Icons ................4-21 Lower Cursor Buttons ................... 4-21 Warning Lamps ....................
  • Page 7 Table of Contents Engine Protection Shutdown Override ............7-13 Shutting the Engine Off ..................7-13 Generation IV Sonic Sensor Cleaning ..............7-14 Pressure Cleaning ....................7-15 Inducements ......................7-15 Inducements Impacts ..................7-16 Final Inducement ....................7-16 DEF Related Inducements .................. 7-16 Tampering/Malfunction ...................
  • Page 8 Table of Contents Change Engine Oil and Filter ................9-7 Inspect Engine Belt ....................9-8 Check Engine Coolant ..................9-8 Replace Engine Coolant ..................9-9 Inspect Cooler Assembly ................... 9-10 Inspect Cooler Fan ....................9-11 Aftertreatment System .....................9-11 Miscellaneous ......................9-11 Flush DEF Tank and Replace Filter ...............9-11 Maintenance 1 - Supply Module ..............
  • Page 9 Table of Contents Storing the Machine ....................10-2 Machine Storage Preparation ................10-2 Release Track Tension ..................10-2 Operations Manual Date May 2020 CR 820 T Page 7...
  • Page 10 Table of Contents Intentionally Left Blank Date May 2020 Operations Manual Page 8 CR 820 T...

  • Page 11: Introduction

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

  • Page 12: Notes To The Operations Manual

    1 INTRODUCTION Notes to the Operations Man- Safety Notes In the operations manuals all safety notes will cov- er ANSI versions. These safety instructions must These operating instructions contain important in- be fully read and understood before carrying out formation on operating the machine safely, properly any work with, or on, the machine.

  • Page 13: Usa Federal Clean Air Act

    1 INTRODUCTION USA Federal Clean Air Act Normal Non-Road Engine Use The maintenance instructions are based on the The Federal Clean Air Act Section 203a(3) prohib- assumption that this conventional machine will be its the removal of air pollution control devices or the used as designated in the operator’s instruction modification of an EPA certified non-road engine to...

  • Page 14: Preventative Maintenance Program

    1 INTRODUCTION Check the condition of the fuel hoses For scheduled service or maintenance, it is advis- able to contact a local authorised dealer or dis- for: tributor in advance to arrange for an appointment • Ageing to ensure availability of the correct equipment and qualified service technician to work on the machine.

  • Page 15: Bulletin Compliance

    1 INTRODUCTION Bulletin Compliance Register Machine When necessary safety related bulletins will be is- Your dealer will register your machine and its war- sued for this equipment. these bulletins must be ranty with the factory. complied with to protect personnel and equipment. Bulletings will be sent to the current owner of re- Transfer of Machine Owner- cord so it is very important for new owners to con-...
  • Page 16 1 INTRODUCTION Intentionally Left Blank Date May 2020 Operations Manual Page 1-6 CR 820 T...

  • Page 17: Safety

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

  • Page 18: Owners, Users, And Operators

    2 Safety Owners, Users, and Operators: alert symbol in order to avoid injury or fatal acci- dents. We appreciate your choice of our machine for your application. Our number one priority is user safety. ANSI Hazard Classification Sys- In order to make a major contribution to safety, the machine owner, user, and operator must: •...

  • Page 19: Property Damage

    2 Safety Property Damage Procedure This indicates a procedure that must be followed This indicates a message related to property dam- step by step for safe operation. Make sure all safety age. The safety alert symbol is not shown with this classification.

  • Page 20: Safety Sign Maintenance

    2 Safety Safety Sign Maintenance Burn Hazard Safety signs are designed and fitted to the machine Burns from hot asphalt mix. to warn of possible dangers, and MUST be replaced immediately if they become unreadable or lost. If the machine is repaired and parts have been replaced Burn Avoidance on which safety signs were fixed, be sure new safety Stay away from hot asphalt.

  • Page 21: Ansi Decals

    2 Safety ANSI Decals Crush Hazard Crush from runaway machine. Crush Avoidance Place machine on level ground and block wheels. Explosion Hazard Battery explosion. Explosion Avoidance Keep open flames away. Decal #1 - Crush Hazard Hopper Wings 0449150006 Explosion Avoidance Do not smoke.
  • Page 22 2 Safety Decal #5 - Safety Crush Hood 0449150004 Decal #3 - Safety Crush Auger 0449040004 Decal #6 - Safety Fall 0449150007 Decal #4 - Safety Burn Hot Asphalt 0449150003 Decal #7 - Safety Entanglement 0449150016 Date May 2020 Operations Manual Page 2-6 CR 820 T...
  • Page 23 2 Safety Decal #8 - Safety Hearing Hazard 0449150005 Decal #10 - Safety Injection 0449150010 Decal #9 - Safety Runaway Machine 0449150011 Operations Manual Date May 2020 CR 820 T Page 2-7...
  • Page 24 2 Safety Decal #11 - Safety Explosion Hazard 0449040014 Decal #12 - Safety Accumlator Dry Nitrogen 0449040012 Date May 2020 Operations Manual Page 2-8 CR 820 T...

  • Page 25: Additional Decals

    2 Safety Additional Decals Decal #13 - Emergency Towing 0449410301 Decal #14 - Paver Patents 05020030 Operations Manual Date May 2020 CR 820 T Page 2-9...
  • Page 26 2 Safety Decal #15 - Hot Mix and Lubrication 91312954 Decal #16 - Tie Down Points 05020034 Date May 2020 Operations Manual Page 2-10 CR 820 T...
  • Page 27 2 Safety Decal #17 - Paver Lifting Points 91313699 Decal #18 -Paver Serial Plate 91311979 Operations Manual Date May 2020 CR 820 T Page 2-11...
  • Page 28 2 Safety Decal #19 -California Prop 65 00833968 Decal #20 -Do Not Step 0449350005 Decal #21 - Lift Point 0449350001 Decal #22 - Tie Down Point 0449350003 Date May 2020 Operations Manual Page 2-12 CR 820 T...
  • Page 29 2 Safety Decal #23 -Paver Moving Instructions 91312955 Operations Manual Date May 2020 CR 820 T Page 2-13...
  • Page 30 2 Safety Decal #24 -Emblem SMV 04418197 Decal #25 -Vacuum Indicator 04418934 Date May 2020 Operations Manual Page 2-14 CR 820 T...
  • Page 31 2 Safety Decal #26 - Crush Warning 05020951 Decal #27 - Emulsion Fill 00833599 Operations Manual Date May 2020 CR 820 T Page 2-15...

  • Page 32: Safety Sign Locations

    2 Safety Safety Sign Locations Figure 2.1 - Left Side View Figure 2.2 - Rear View Date May 2020 Operations Manual Page 2-16 CR 820 T...
  • Page 33 2 Safety Figure 2.3 - Right Side View Figure 2.4 - Front View Operations Manual Date May 2020 CR 820 T Page 2-17...

  • Page 34: Personal Safety

    2 Safety Personal Safety ing service or repair could cause personal injury or death. Make it impossible for anyone to start this In addition to the specific maintenance and operat- machine while others work on it or in it. Before per- ing instructions in this manual, the operator must forming work always: read and understand all instructions in this chapter.

  • Page 35: Operation Of Control Interlocks

    2 Safety Operation of Control Interlocks and shields when the task for which you removed them is finished. The engine cannot be started unless both of the Never attempt to clear away jammed feed material, propulsion control levers arein neutral (the center discharge material, or other stoppage while the ma- position) and the emergency stop switches are dis- chine is running.

  • Page 36: Safe Paver Operation

    2 Safety Chips or other debris can fly off objects when struck. Before leaving the operator’s seat, stop the paver Always use proper personal protective equipment by putting the FNR in the STOP position and set- and make sure that no one can be injured by flying ting the parking brake.

  • Page 37: Questions

    2 Safety marked containers and away from all unauthorized Repair any loose or damaged fuel lines. Leaks can personnel. cause fires. Store all oily rags or other flammable material in a Make sure that all clamps, guards and heat shields protective container in a safe place.
  • Page 38 2 Safety Intentionally Left Blank Date May 2020 Operations Manual Page 2-22 CR 820 T...

  • Page 39: Technical Data

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

  • Page 40: Dimensions

    3 Technical Data CR820T Rubber Track Asphalt Paver Dimensions Width ................8’-11” (2.72 M) Height (Frame Lowered) ..........10’-6” (3.20 M) Length with Stretch 16 Screed ..........20’-8” (6.30 M) Average Shipping Weight Tractor ................31,600 lb. (14 333 kg) with Stretch 16 Screed ............36,400 lb. (16 510 kg) Capacities Diesel Fuel ..............48 Gal (182 L) Hydraulic Oil ..............50 Gal (189 L)

  • Page 41: Operator Controls

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

  • Page 42: Controls

    4 Operator Controls Controls Figure 4.1 - Control Panel 1. Hopper Wings - The hopper raise switch engage speed and counterclockwise to is spring-loaded to automatically return to engage the truck hook quicker. the neutral position when released. It must 3.
  • Page 43 4 Operator Controls rear of the paver will lower. • P/4 - (if the paver is not equipped with the optional Front Wheel Assist, it op- This switch allows the operator to elevate erates the same as for P/2.) Use this the rear of the tractor to give maximum position to change to front wheel assist.

  • Page 44: Screed Controls

    4 Operator Controls 14. Speed Control Knob - works in conjunction 19. Console Control Button - Operator pres- with FNR to set ground speed - This dial is ence selection is the method used by the used to govern the maximum travel speed operator to enable either the right or left of the paver.

  • Page 45: Operator's Console

    4 Operator Controls Operator’s Console Figure 4.2 - Display Icon Buttons Operations Manual Date May 2020 CR 820 T Page 4-5...

  • Page 46: Display Icon Buttons

    4 Operator Controls Display Icon Buttons Front Wheel Assist Item Symbol Description Advanced Diagnostics Home Advanced Functions Low Hopper Alarm Diagnostics Paver Diagnostics Descending Values Save Engine Diagnostics Setup (Calibration) Beacon (Flasher) Steering Fuel Tank Incrementing Values Fuel Tank Left (Not appli- cable to the CR554) Uphill Mode Fuel Tank Right (Not appli-...

  • Page 47: Additional Display Icon Buttons

    4 Operator Controls Additional Display Icon Buttons Left Spreading Item Symbol Description Auger/Converyor *Animated Motion (ON) Console Status *Green (Active) Right Spreading *Red (Inactive) Auger/Conveyor *Animated Motion (ON) Auto Throttle Travel Mode Screed Assist Closed Loop Steering Screed Vibrators *Animated Motion (ON) Center Steering Operations Manual Date May 2020...
  • Page 48 4 Operator Controls 4 10 1 Figure 4.3 Warning Icons Date May 2020 Operations Manual Page 4-8 CR 820 T...

  • Page 49: Warning Lamp Icons

    4 Operator Controls Warning Lamp Icons Item Symbol Description HEST Battery Voltage Hydraulic Temp Coolant Temp Parking Brake *Green - AutoBrake (ON)/ DEF Level Brake (OFF) *Red - Brake (ON) *Flashing Red/Green - Engine Warning AutoBrake (ON)/Brake (ON) (Red - Stop Engine) (Yellow - Warning) Wait to Start Engine Oil Pressure...

  • Page 50: Operator's Display

    4 Operator Controls Operator’s Display Splash Screen When the engine ignition switch is turned to the ON Display Screens position, the micro controller is powered up. The Splash screen is the first screen that is displayed. The operator display provides basic information The Splash screen will switch to the Main Run about the operation of the machine, engine fault screen after a few seconds.
  • Page 51 4 Operator Controls Figure 4.5 - Main Run Screen with Message Center Operations Manual Date May 2020 CR 820 T Page 4-11...
  • Page 52 4 Operator Controls Figure 4.6 - Main Run Screen Date May 2020 Operations Manual Page 4-12 CR 820 T...

  • Page 53: Main Run #1 Screen

    4 Operator Controls Main Run #1 Screen minute up to 120 feet-per-minute. Paver ground speeds greater than 120 feet-per- After the splash screen is displayed for a few sec- minute are depicted in miles-per-hour. The onds, the micro controller displays the Main Run #1 Ground Speed is also displayed in gauge screen.

  • Page 54: Left Side Button Icons

    4 Operator Controls Left Side Button Icons • Advance Functions Menu (22, Figure 4.6) is displayed adjacent to the third from the • Warning Beacon ON/OFF (16, Figure 4.6) is top button (Button #7). Navigation to the displayed adjacent to the top button (Button Advance Functions Screen is accomplished #1).

  • Page 55: Warning Lamps

    4 Operator Controls Warning Lamps Main Run #2 Screen Several screens display the Engine and Tractor Pressing (5) RIGHT <►> button while the Main “Warning Icons” on page 4-8 that are located Run #1 screen is displayed will navigate to the across the top of the screen.
  • Page 56 4 Operator Controls Figure 4.9 - Main Run Screen Date May 2020 Operations Manual Page 4-16 CR 820 T...

  • Page 57: Left Gauge Cluster

    4 Operator Controls Left Gauge Cluster Ground Speed is also displayed in gauge format to a maximum of 80 feet-per-min- • DEF Tank Fluid Level (2A, Figure 4.8) is ute. displayed digitally. • Propel % (10, Figure 4.8) is displayed digi- •...

  • Page 58: Left Side Button Icons

    4 Operator Controls Left Side Button Icons • Advance Functions Menu (22, Figure 4.6) is displayed adjacent to the third from the • Warning Beacon ON/OFF (16, Figure 4.6) is top button (Button #7). Navigation to the displayed adjacent to the top button (Button Advance Functions Screen is accomplished #1).

  • Page 59: Warning Lamps

    4 Operator Controls Advanced Functions Screen Warning Lamps Several screens display the Engine and Tractor Pressing (2) Advanced Functions button while either “Warning Icons” on page 4-8 that are located the Main Run #1 or Main Run #2 screen is displayed across the top of the screen.

  • Page 60: Left Of Center Gauge Cluster

    4 Operator Controls Left of Center Gauge Cluster side of the turn indicators. The icon (green auger) will become animat- • Screed Assist icon (C, Figure 4.11) will ed when the system is enabled by utilizing show when ON. the left-hand and right-hand switches for the •...

  • Page 61: Right Side Button Icons

    4 Operator Controls ACTIVE or turned DISABLED by pressing button #44. A green icon indicated that the Closed Loop Steering function is ACTIVE. A blue icon indicated that the Close Loop Steeering function is DISABLED. • Center Steering (45, Figure 4.11) ON/OFF is displayed adjacent to the third from the top button.

  • Page 62: Ground Controls, Gauges, And Levers

    4 Operator Controls Ground Controls, Gauges, Master Switch and Levers This section describes the other controls for the machine that are not operated by the operator’s control panel. Vacuum Indicator Figure 4.14 - Master Switch The master switch (2) must be in the ON position before the machine can be started.

  • Page 63: Shipping And Lifting

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

  • Page 64: Receive The Machine

    5 Shipping and Lifting Machine Receive the Machine Load/Unload Paver on/off a Trailer Initial Inspection of the Equipment Ground Clearance As each load is signed for and accepted by the car- rier, it becomes the property of the purchaser. To The paver can be loaded or unloaded from vari- avoid forfeiting claims, any damage—whether ob- ous kinds of trailers.

  • Page 65: Driving The Paver On/Off The Trailer

    5 Shipping and Lifting Machine ing the total machine weight. If screed is attached, always ensure the screed is up and locked. Insufficient ground clearance Figure 5.2 - Remove all chains and binders from the paver Pavers have a frame raise feature that allows the frame.

  • Page 66: Preparation For Transport

    5 Shipping and Lifting Machine Preparation for Transport Do not set the screed on nails, rivets, or bolts. These can cause damage to the screed bottom. Chaining directly to the screed, truck hook, or tow arms could damage the equipment. When chain- ing the machine to the trailer, all chains should be secured to the machine frame only.
  • Page 67 5 Shipping and Lifting Machine Rear Tie-down Shackle Figure 5.7 - 5. Connect chains and chain binders to the tie-down shackles (1) at the rear of the paver. Figure 5.5 - Control Panel 3. Use the frame raise switch (6) on the op- erator’s console to lower the rear of the paver as much as possible.
  • Page 68 5 Shipping and Lifting Machine Intentionally Left Blank Date May 2020 Operations Manual Page 5-6 CR 820 T...

  • Page 69: Initial Setup And Adjustments

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

  • Page 70: Unload And Install The Screed

    6 Initial Setup and Adjustments Unload and Install the Screed Sometimes the screed will be shipped separately from the tractor. In these cases the screed will need to be installed before beginning operation. • Place blocks on a flat level surface where the screed can be installed. •...
  • Page 71 6 Initial Setup and Adjustments Figure 6.2 - Screed Connections a. Hydraulic hoses from the left hand screed valve assembly to the male and female connections (3) on the tractor. b. Hydraulic hose (4) from the center vibrator tees to the left side auger motor. c.
  • Page 72 6 Initial Setup and Adjustments Intentionally Left Blank Date May 2020 Operations Manual Page 6-4 CR 820 T...

  • Page 73: Standard Operating Procedures

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

  • Page 74: Pre-Operating Checks

    7 Standard Operating Procedures Pre-Operating Checks Raising the Center Hood The hood safety latch will engage only when the hood is fully raised. Keep all personnel out from under the hood until the safety latch is engaged. Failure to follow these instructions could result in death or serious injury.

  • Page 75: Lowering The Center Hood

    7 Standard Operating Procedures Lowering the Center Hood Figure 7.3 shows the center hood safety latch in Keep all personnel out from under the center hood the locked position. Through the R/H hood access during the lowering procedure. Failure to follow door, raise the center hood a bit to remove the these instructions could result in death or serious weight from the safety latch, then pull down on the...

  • Page 76: Inspection

    7 Standard Operating Procedures Inspection Figure 7.6 - Inspection Areas 1. Before the start of each day, walk around the machine and check for the following: a. Inspect any attachments for damage or excessive wear. b. Inspect the radiator guard for trash buildup. c.

  • Page 77: Start Up

    7 Standard Operating Procedures Start Up and that the keyswitch is on the left side console. Set the console switches and controls as follows: Starting the Engine To prevent damage to the starting motor, do not en- gage the starting motor for more than 30 seconds. Wait 2 minutes between each attempt to start.

  • Page 78: Preparing To Pave

    7 Standard Operating Procedures Preparing to Pave 8. Once the screed lock arm (1 7.10) has passed below the block-off cam (2 7.10) on both sides, you can release the screed Raise/Lower Screed unlock toggle. Fume Recovery System The fume recovery system is designed to collect fumes given off by hot mix asphalt and discharge them away from operator work areas.

  • Page 79: Fume Fan Speed Control

    7 Standard Operating Procedures Null the Screed The fume extraction system should be checked for proper function prior to paving. With the engine run- ning open the fan control valve until you can hear the fan spinning. If there is a restriction in the sys- tem the vacuum gauge will read above 0 in H2O.

  • Page 80: Joints

    7 Standard Operating Procedures Transverse Joints Turn both manual depth cranks (2) on the screed until the screed face is resting flat on the boards. Transverse joints are created when an existing mat When the screed is resting flat on the boards the or lane is to be continued. The quality and durability hand cranks will have a small area of free rotary of the joint depends on careful preparation of the movement where little resistance is felt, which indi- existing mat or lane.
  • Page 81 7 Standard Operating Procedures Fill the auger chamber no more than 1/2 an auger level. Do not over fill the auger chamber, as this is the most common cause of creating a bump just after pulling off a joint. If needed, the corner areas on the ends of the screed should be hand-filled to prevent force feeding an excessive high head of material in the center areas of the screed.

  • Page 82: Operating Hints

    7 Standard Operating Procedures Hydraulic Tunnel low. This could cause a premature joint failure. If there is too much material in the joint area a bump will be produced. Operating Hints The following are some specific considerations for operation of asphalt pavers. While not all-inclusive, following these recommendations should reduce the risk of problems and improve rubber track dura- bility and reliability.

  • Page 83: Manual Material Retaining Plates

    7 Standard Operating Procedures Manual Material Retaining Plates Machines are shipped with the manual material re- taining plates retracted. To work properly, the plates must have the bottom edge of the plate below the bottom edge of the machine frame bulkhead and be extended.

  • Page 84: Electrical System

    7 Standard Operating Procedures Electrical System Coolant Temp Engine Protection System Illuminated Red if temp > 230F ESC Lamp Oil Pressure Exhaust System Cleaning Illuminated Red is engine oil pres- sure <15 PSI (Engine must be running) DEF Lamp System Voltage Diesel Exhaust Fluid Illuminates Yellow if system voltage <9 VDC...

  • Page 85: Engine Protection Shutdown

    7 Standard Operating Procedures The engine is equipped with an engine protection There are three types of system codes: system which monitors critical engine tempera- • Engine electronic control system fault tures and pressures and will log diagnostic faults codes when an over or under normal operation condition •...

  • Page 86: Generation Iv Sonic Sensor Cleaning

    7 Standard Operating Procedures with asphalt. Refer to the Maintenance chapter for information on when and how to clean fume recov- ery system fan and/or tubes. Hot mix gets hard quickly. Do not allow mix to cool Generation IV Sonic Sensor in the hopper.

  • Page 87: Pressure Cleaning

    7 Standard Operating Procedures Pressure Cleaning Do not spray directly at electrical components, seals, bearings, gearboxes, or hydraulic cylinder rods. Water can be forced into electrical connec- The entire paver can be pressure-washed to re- tions or the hydraulic system which could damage move dirt and grease.

  • Page 88: Inducements Impacts

    7 Standard Operating Procedures Inducements Impacts There are multiple conditions that can cause the the Inducement Strategy to engage. Use the SPN-FMI reporting in the Active Faults Screen on the operator display to help pinpoint what is causing the problem. In general, it is best practice to address any problems as soon as a STOP or WARN illumination is observed, rather than after Inducements kick in –...
  • Page 89 7 Standard Operating Procedures Adequate DEF Quality is essential to meet- 70027.The following conditions are optimal for ing emission targets. If an issue with the DEF maintaining DEF Quality and shelf life during Quality is detected, the ECM will warn the op- prolonged transportation and storage: erator by use of the DEF and/or WARN lamps.

  • Page 90: Tampering/Malfunction

    7 Standard Operating Procedures Tampering/Malfunction • Disconnected DEF Dosing Valve • Disconnected Supply Module Hardware or Performance issues will cause NOx emissions to rise above acceptable limits. When • Disconnected NOx sensor(s) or Tempera- this happens, the ECM uses the DEF, WARN, and ture Modules STOP icon illumination (along with messages trans- •...

  • Page 91: Primary/Secondary Inducement

    7 Standard Operating Procedures Figure 7.30 - Aftertreatment Tampering/Malfunction 2 Primary/Secondary Induce- When working to clear Faults/Warnings, be sure to power cycle the system after making repairs to ment ensure that the operator display refreshes the Ac- tive Faults screen. Best practice is to power down the unit prior to making repairs, and power back Deactivation up to verify.

  • Page 92: Esc - Exhaust System Cleaning

    7 Standard Operating Procedures ESC - Exhaust System Clean- SPN 3712 – FMI 0 = Aftertreatment SCR Induce- ment – Most Severe Like with Primary & Secondary Inducement, the Exhaust System Cleaning is an automatic process first step is to clear all other codes except for the initiated by the ECM to reduce particulates and above two.

  • Page 93: Emergency Procedures

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

  • Page 94: Engine Start-Up After Stall

    8 Emergency Procedures Engine Start-up After Stall Connect the negative (-) cable (2) to the paver frame away from the battery. The negative (-) cable Under certain conditions the engine could stall should always be connected away from the battery. while under load.

  • Page 95: Emergency Stop

    8 Emergency Procedures Emergency Stop A lockout and tagout should be performed in the following situations: • Any time anyone is maintaining, repairing, lubricating, or, for whatever reason, work- ing on the equipment. • When the equipment is broken, or, for whatever reason, unfit or unsafe to oper- ate.

  • Page 96: Emergency Towing

    8 Emergency Procedures The only person who is permitted to remove a lock Attaching chains to the push roller frame or truck and tag is the one who applied them. Before re- hook frame could result in serious and expensive moving a lock and tag: damage.
  • Page 97 8 Emergency Procedures of the cartridge assembly. Rotate the middle hex 3 revolutions counterclockwise to open the bypass. DO NOT rotate more than 3-1/2 revolutions, as ad- ditional rotation will permit external leakage. To close the bypass valve, rotate the middle hex clockwise until it is seated.
  • Page 98 8 Emergency Procedures Intentionally Left Blank Date May 2020 Operations Manual Page 8-6 CR 820 T...

  • Page 99: Maintenance

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

  • Page 100: Service Parts

    9 Maintenance Service Parts Only use company authorized parts when performing maintenance and repair procedures. Maintenance Schedule When Needed Item Service Lube Pump Drive Belts Adjust the tension. * DEF Supply Module Replace filter. * DEF Tank Filter Replace filter. For primary and secondary air filters, check Air Inlet System the restriction indicator and replace as needed...

  • Page 101: After First 40 Service Hours Only

    9 Maintenance After First 40 Service Hours Only Item Service Lube 80W-140 Final Drive Oil Check. Synthetic Spreading Auger Check. EP1 or EP2 80W-140 Speed Reducer Check. Synthetic With engine off, check generator main phase Generator circuits. Tighten as required. Every 40 Service Hours Item Service...

  • Page 102: After First 500 Service Hours

    9 Maintenance After First 500 Service Hours Item Service Lube Engne Change Oil and Filter 15W-40 Hydraulic Tank Replace the hydraulic fluid after the first 500 hours IS AW 68 of operation in a new paver or a paver that has just had a new hydraulic pump or motor installed.

  • Page 103: Systems

    9 Maintenance Systems Engine power and speed will be gradually reduced depending on the level of severity of the observed Electronic Controlled Fuel System condition until the engine shuts down. The engine control system is an electronically op- Hydraulic Fluid Reservoir erated fuel control system that also provides many operator and equipment features.

  • Page 104: Filters

    9 Maintenance Filters Engine The paver has five spin-on hydraulic fluid filters and two suction strainers for maximum component pro- tection. There are two travel circuit charge filters, two conveyor drive charge filters, and one auxiliary pump filter. Two filters mounted underneath the aftertreatment filter the fluid coming from the charge section of the left travel and conveyor pumps through the filters and back to their respective pumps.

  • Page 105: Change Engine Oil And Filter

    9 Maintenance Drain the oil only when it is hot and the contami- Wait at least 5 minutes after shutting off the engine nants are in suspension. to check the oil. This allows time for the oil to drain to the oil pan. Operate the engine until the engine coolant tem- perature reaches 140°F (60°C).

  • Page 106: Inspect Engine Belt

    9 Maintenance Check Engine Coolant Install the filter onto the engine until the filter makes good contact, then rotate the filter another 3/4 of a turn. Remove the dipstick to check the oil level. Add oil as needed. Do not remove the radiator cap from a hot engine. Never operate the engine with the oil level below Wait until the temperature is below 120°F (49°C) the “L”...

  • Page 107: Replace Engine Coolant

    9 Maintenance Replace Engine Coolant Do not remove the radiator cap from a hot engine. Wait until the temperature is below 120°F (50°C) before removing the pressure cap. Failure to do so can result in personal injury from heated coolant spray or steam.

  • Page 108: Inspect Cooler Assembly

    9 Maintenance Inspect Cooler Assembly Figure 9.11 - Cooler Assembly Paving conditions will determine how often the cool- er assembly needs to be inspected and cleaned. If Figure 9.9 - Radiator Cap Location severe conditions exist or there are a lot of airborne contaminates, it may be necessary to inspect and The hood has a lockable access door that is in the clean the cooler assembly more than once a day.

  • Page 109: Inspect Cooler Fan

    9 Maintenance Inspect Cooler Fan Miscellaneous A visual inspection of the cooler fan is required Flush DEF Tank and Replace Filter daily. Personal injury can result from a fan blade failure. Pulling or prying on the fan can damage the fan blade and cause fan failure.

  • Page 110: Maintenance 1 - Supply Module

    9 Maintenance Maintenance 1 - Supply Module The Aftertreatment System contains 2 serviceable filters – a Suction Filter in the DEF Tank and a System Filter in the Supply Module: Figure 9.15 - Aftertreatment Maintenance Supply Module Air Intake System Running the machine with an air cleaner that needs replacement does not allow the engine to get the Replace Primary Air Filter Element...

  • Page 111: Replace Secondary Air Filter Element

    9 Maintenance Replace Secondary Air Filter Ele- ment The primary filter element is replaced every 250 service hours. The secondary filter element is re- placed every 500 service hours. This means that every second time that the primary filter element is replaced, the secondary filter element will also be replaced.

  • Page 112: Check Air Inlet Connections

    9 Maintenance the air inlet system does not leak. The air inlet system includes the piping from the air cleaner to the turbocharger and the piping from the turbo charger to the after cooler or inlet manifold depending on model. Fuel System Check Fuel Level Keep away from sparks or open flame while work-...

  • Page 113: Drain Fuel Filter/Water Separator

    9 Maintenance Drain Fuel Filter/Water Separator Replace Fuel Filter/Water Separa- Drain the water and sediment from the separator daily. When installing a replacement filter element, keep in mind that overtightening may distort the threads or damage the filter element. Figure 9.21 - Fuel Filter/Water Separator Shut off the engine and allow it to cool.

  • Page 114: Hydraulic System

    9 Maintenance Hydraulic System When adding oil, add until the FULL COLD level is reached on the sight glass. Do not add beyond Check Hydraulic Tank Oil Level this point as overfilling the hydraulic tank does not leave room for thermal expansion when the oil is at running temperature.

  • Page 115: Check Hydraulic Lines And Components

    9 Maintenance Clean the cover (4) to prevent dirt from falling into the hydraulic reservoir. Remove the cover to gain access to the strainers (5). Remove the strainer from the suction manifold. Be Unbolt the hose (1) from the left side of the main- careful not to knock contaminants off the outside of frame and route it down and out the bottom of the the strainer as it is removed from the manifold.

  • Page 116: Replace Charge Filters

    9 Maintenance Clean the head where the filter element seats. Apply a thin film of clean hydraulic oil to the threads Replace Charge Filters on the head and to the element gasket. Install the filter by hand until the element touches the head.

  • Page 117: Adjust Pump Drive Belt Tension

    9 Maintenance Adjust Pump Drive Belt Tension Check the poly chain belt tension only after the en- tire machine is at operating temperature (minimum of two hours of continuous paving operation) Do not overtighten belts. Overtightening the belts can cause premature belt and/or bearing failure. Figure 9.32 - Access Covers Loosen the belt access cover bolts, then rotate the Tension values for poly chain belts are tempera-...
  • Page 118 9 Maintenance » As the plunger is pushed down, the small o-ring will slide up the scale. Remove the tester. Read the belt deflection force in pounds at the small o-ring. Compare the value with the table below. Ref. Table 9.1.

  • Page 119: Electrical System

    9 Maintenance Loosen nuts (5) on the pump assembly for the belt When removing the battery cables, always remove being adjusted. Loosen the nuts just enough to al- the negative terminal first then the positive termi- low the pump assembly to slide. nal.

  • Page 120: Storing Batteries

    9 Maintenance Storing Batteries Verify that there is no hydraulic oil in the final drive housing before adding gear oil. Hydraulic oil in this If the machine will be stored for more than 30 days, housing indicates leakage from the brake or hy- remove the battery.

  • Page 121: Slat Conveyor System

    9 Maintenance Figure 9.41 - Inner Rear Conveyor Bearing Fit- tings Figure 9.39 - Final Drive in Level Check Position Rotate the drive until the fill plug (1) is straight up and the level check plug (2) is 90° down from the fill plug.

  • Page 122: Check And Adjust Spreading Auger Drive Chains

    9 Maintenance Lubrication Check and Adjust Spreading Au- ger Drive Chains Figure 9.44 - Spreading Auger Bearing • Lubricate the Spreading Auger Bearings, one on left and one on right. (1). Clean Truck Hitch Figure 9.43 - Drive Chain Adjustment The truck hitch should be cleaned to remove any asphalt that has collected on the truck hook or roll- ers.

  • Page 123: Clean Fume Recovery System

    9 Maintenance full throttle, the vacuum indicator (1) should regis- ter a reading. When the vacuum indicator reading is too low, components of the fume recovery sys- tem require cleaning or maintenance. See below for cleaning procedures. See the Troubleshooting Check all hoses and for cracks, cuts, dents, or col- chapter for more information about maintenance.

  • Page 124: Tracks Corrective Maintenance

    9 Maintenance • Check the track alignment. Rubber track undercarriage component alignment is very important to the life of the track. An easy, quick check is to inspect the track center lugs. Figure 9.49 - Fume Recovery System Fan 3 •...

  • Page 125: Check Hood Raise Reservoir Oil Level

    9 Maintenance • Periodically check that the track is properly tensioned. A loose track could cause de-tracking. Figure 9.51 - Track Nomenclature Use the following table to record the information off the tracks on your machine. Data Machine Serial Number Hour Meter Reading Date of Track 1st Use Right Track...
  • Page 126 9 Maintenance Intentionally Left Blank Date May 2020 Operations Manual Page 9-28 CR 820 T...

  • Page 127: 10 Storage

    10 Storage 10 STORAGE Operations Manual Date May 2020 CR 820 T Page 10-1...
  • Page 128 10 Storage Storing the Machine Machine Storage Preparation Release Track Tension The following procedures are recommended for Park the machine on level ground. conditioning the machine for storage. Shut off the engine and remove the key from the • Run all material completely out of the ma- ignition.
  • Page 129 Intentionally Left Blank...
  • Page 130 BOMAG Americas, Inc. 125 Blue Granite Parkway, Ridgeway, South Carolina 29130, U.S.A. (800) 782-6624 Printed in U.S.A.

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