LeeBoy 8520C Safety And Operation Manual
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LeeBoy 8520C Safety And Operation Manual

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Safety and Operations Manual
LEEBOY MODEL 8520C CONVEYOR PAVER
Manual No. 1027277-SOP
Manual No. 1027277-SOP
REV A
REV A
This manual applies to
Serial Number 367609
and above.

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Summary of Contents for LeeBoy 8520C

  • Page 1 Safety and Operations Manual LEEBOY MODEL 8520C CONVEYOR PAVER Manual No. 1027277-SOP Manual No. 1027277-SOP REV A REV A This manual applies to Serial Number 367609 and above.
  • Page 3 The LeeBoy family of companies is committed to total quality management with a strong focus on meeting customer needs. LeeBoy is also proud to be an accredited ANAB manufacturer, which is a certification process comprised of quality standards established by the American National Standards Institute (ANSI) and the American Society for Quality (ASQ).
  • Page 4 2023 LeeBoy 2023 LeeBoy LeeBoy reserves all copyright and other rights in this manual and its content. No part of this manual may be reproduced or used in any way without the written permission of LeeBoy, except as necessary to operate LeeBoy equipment.

  • Page 5: Table Of Contents

    Hydraulic Fittings ......2-8 Determining Proper Torque ..... 2-9 LeeBoy 8520C Conveyor Paver...
  • Page 6 Perform Parked Regeneration ....4-21 Status and Warning Alert Icons ....4-24 LeeBoy 8520C Conveyor Paver...
  • Page 7 Tool Rack ......4-44 Hydraulic Tow Points ......4-44 LeeBoy 8520C Conveyor Paver...
  • Page 8 Change Engine Oil and Filter ..... 5-18 Change Air Filter ......5-19 viii LeeBoy 8520C Conveyor Paver...
  • Page 9 Track Tension Cylinder ..... . . 5-38 Track Rollers ......5-39 LeeBoy 8520C Conveyor Paver...
  • Page 10 PV485 Troubleshooting ..... . . 5-64 Plus One Controller ......5-66 LeeBoy 8520C Conveyor Paver...

  • Page 11: Safety

    Decal Installation (Sticker Type) ....1-12 Decal Installation (Top Protected) ....1-12 LeeBoy 8520C Conveyor Paver...

  • Page 12: Safety

    Safety NOTES LeeBoy 8520BCConveyor Paver...
  • Page 13 IMPORTANT FOR THE SAFETY OF YOU AND YOUR COWORKERS. READ AND UNDERSTAND read and understand this manual before operating the LeeBoy Model 8520B Conveyor Paver and follow its THOROUGHLY. HEED THE WARNINGS AND instructions when operating the machine. FOLLOW THE INSTRUCTIONS.

  • Page 14: Safety Precautions

    • Failure to observe these directions could result in electrocution or death. • Contact LeeBoy or an authorized LeeBoy dealer for additional training. • Make sure you are aware of all laws and regulations Electrocution Hazard...
  • Page 15 When operating machinery there is a risk for Never modify the LeeBoy machine without the written fire. Always have appropriate safety consent of LeeBoy. Any modification can affect the safe equipment available. operation of the paver and may cause personal injury or death.
  • Page 16 • Never check for a hydraulic fluid or fuel leak with your hands. Always use a piece of wood or cardboard. Have your authorized LeeBoy dealer or distributor repair the damaged parts. LeeBoy 8520BCConveyor Paver...

  • Page 17: Machine Precautions

    Natural separation will occur in about 48 to 72 hours. • Only use replacement parts approved by LeeBoy. Get medical attention as soon as possible. Other replacement parts may affect warranty •...

  • Page 18: Refueling Precautions

    • Check brakes, steering and other control devices in there is danger of a slide. accordance with instructions before starting. Be sure both steering levers (joysticks) are in neutral with the neutral lock engaged. LeeBoy 8520BCConveyor Paver...

  • Page 19: Poor Visibility

    While the machine is equipped with a beacon and a 3. Lower screed to ground or lock the screed in the work light, contact your authorized LeeBoy dealer for upright position. additional lighting packages if working under these 4.

  • Page 20: Safety Decals

    DANGER safety decals as shown in the following readable and located on the paver as designated by graphics. For additional help, LeeBoy. contact your authorized LeeBoy dealer to order a replacement kit. Safety Decal Locations Safety Decal Locations Part # 856441...
  • Page 21 Part # 856446 Left Side Part # 859764 Part # 856598 Both Sides Part # 856598 Part # 859801 Part # 856442 Both Sides Part # 1010489 (Top of Screed Extension) Both Sides Both Sides LeeBoy 8520C Conveyor Paver 1-11...

  • Page 22: Safety Decals Care

    5. Slowly remove remaining backing and carefully smooth into place. • Obtain replacement safety decals or signs from your authorized dealer. 6. Small air pockets can be pierced with a pin and smoothed using a piece of decal backing. 1-12 LeeBoy 8520BCConveyor Paver...

  • Page 23: Information And Specifications

    Hydraulic Fittings ......2-8 Determining Proper Torque ..... 2-9 LeeBoy 8520C Conveyor Paver...

  • Page 24: Two Year Limited Warranty

    Exclusion of Other Warranties/Limitation of Liability Exclusion of Other Warranties/Limitation of Liability OTHER THAN THE EXPRESS WARRANTY PROVIDED IN SECTION A. ABOVE, LEEBOY GIVES NO EXPRESS, STATUTORY, OR IMPLIED WARRANTY OR GUARANTEE AND HEREBY DISCLAIMS ALL SUCH WARRANTIES, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, SUITABILITY, DURABILITY, CONDITION, QUALITY, OR FREEDOM FROM CLAIMS OF ANY PERSON BY WAY OF INTERFERENCE, INFRINGEMENT, OR THE LIKE.

  • Page 25: Contact Information

    Sales Representative: Dealership Name: Dealership Address: Dealership Phone: Record of Ownership Please complete the following information for use if you need to contact LeeBoy for service, parts or literature. Machine Model Number: Product Serial Number: Date of Purchase: Nameplate Nameplate The nameplate contains the model and serial numbers used to identify the machine and its components for parts or service information.

  • Page 26: Specification Charts

    Information and Specifications SPECIFICATION CHARTS The specifications provided in this section include Replace original equipment only with screed weights, dimensions, performance, and torque components approved by your LeeBoy dealer. values for both metric and standard inch fastener. 6.8’ (Low Deck) 6.10’...
  • Page 27 Pump (Propulsion) 3625 psi Cylinder Pump 2400 psi Conveyor Pump 3400 psi Auger Pump 3400 psi Track Tensioning Relief 1200 psi Charge Pressure 350 - 400 psi Track Tension Pressure 175 psi Park Brake Release 290 psi LeeBoy 8520C Conveyor Paver...
  • Page 28 Voltage 240 Volts Frequency 57 - 63 Hz Table 2-11. Track Specifications ITEM SPECIFICATION Length: 5 ft 6 in Poly/Steel (2-Speed, 36 Pads) Width: 1.2 ft Length: 5 ft 6.75 in Rubber (2-Speed) Width: 1.4 ft LeeBoy 8520C Conveyor Paver...

  • Page 29: Torque Specifications

    1520 1139 1817 1363 2464 1848 12 UNF 1241 1683 1261 2012 1509 2728 2046 1-1/2 6 UNC 1950 1462 2644 1982 3162 2371 4287 3215 12 UNF 2194 1645 2975 2230 3557 2668 4823 3617 LeeBoy 8520C Conveyor Paver...

  • Page 30: Metric Fasteners

    Place one wrench on the connector body and tighten the swivel nut with the second to the torque shown in the following table: NOTE: The torque values shown are based upon 1 1/4 lubricated connections. 1 3/8 LeeBoy 8520C Conveyor Paver...

  • Page 31: Determining Proper Torque

    TS = Torque setting indicated on wrench Equations Equations • Torque setting if the crowfoot is placed in line with respect to the wrench: TS = TD * L / LA TS = TD * L / (L+E) LeeBoy 8520C Conveyor Paver...
  • Page 32 2. The flats method is most accurate for the first assembly cycle. For multiple disassembly and assembly cycles, torque values are more reliable. 3. Tightening two (2) flats or more may damage seal faces. LeeBoy 8520C Conveyor Paver 2-10...
  • Page 33 2. Torque values apply to bolts that are plated or coated in light engine oil. 3. Before assembly, lubricate O-Ring with light oil (SAE 10W or 20W). LeeBoy 8520C Conveyor Paver 2-11...
  • Page 34 2. When using a male tapered pipe thread with a female straight or parallel pipe thread, maximum values are 50% of those listed in the table above. 3. If thread sealant is used, maximum values shown should be decreased by 25%. LeeBoy 8520C Conveyor Paver 2-12...

  • Page 35: Component Location

    Screed Control Box ......3-10 Steering and Speed Control Box ..... . 3-11 LeeBoy 8520C Conveyor Paver...

  • Page 36: Component Location

    Component Location NOTES LeeBoy 8520C Conveyor Paver...

  • Page 37: Components Overview

    Engine A powerful, turbo-charged This section describes the major components for the 125 HP engine equipped with LeeBoy 8520C Conveyor Paver. Become familiar with the latest technologies and these components before operating the machine. advanced emission systems allows optimum performance...

  • Page 38: Augers

    The LeeBoy 8520C Conveyor Paver is equipped with a screed operator using the the Heavy Duty 815HD screed. It features heavy-duty remote screed control box.

  • Page 39: Machine Overview

    Crown and Valley Adjusts crown and valley while paving. Tilt Screw Adjusts the tilt of the end gate. Depth Screw Controls asphalt at the end gate (one on each end gate). Adjustable Roller Bar Adjustable Roller Bar LeeBoy 8520C Conveyor Paver...

  • Page 40: Control Panel

    Optional Component: Engages truck hitch function. Engages the truck hitch to the material truck Truck Hitch wheels. Set switch to the IN position to engage the hitch. The OUT position disengages hitch (Option) from the material truck wheels. Ignition Starts and stops engine. LeeBoy 8520C Conveyor Paver...
  • Page 41 Push switch to the IN position to close hopper wings. Extends or retracts right screed extension. (Switch also located on the remote control box. Right Extension Push switch IN to retract right screed extension. Push switch to OUT to extend right screed Switch extension. LeeBoy 8520C Conveyor Paver...

  • Page 42: Screed Controls

    Controls the depth of the asphalt (one on each side of main screed). Adjusts for positive crown or negative valley in wear plate. Crown and Valley Adjuster NOTE: Power Crown option available. Control box for the electric screed heat (and heated endgate option if Electric Heat Box equipped). LeeBoy 8520C Conveyor Paver...

  • Page 43: Screed Electric Heat Controls

    (if equipped with the Automatic Temperature Control option). If equipped with this option, the power crown automatically adjusts positive or negative crown as needed. Power Crown [Option] • Push switch up for increased positive crown. • Push switch down for negative crown (valley). LeeBoy 8520C Conveyor Paver...

  • Page 44: Screed Control Box

    Opens and closes Under Cut-Offs Auger Material Cut-Offs. Sets the thickness of the asphalt and Tow Switch controls the electric tow screws. Extends and retracts Screed Extension Figure 3-6. Screed Control Box screed extension. (Right Control Box Shown) 3-10 LeeBoy 8520C Conveyor Paver...

  • Page 45: Steering And Speed Control Box

    STOP, control station is deactivated, parking brake Run/Stop applied, and machine will Switch not move. When set to RUN, control station is activated, parking brake is released, and machine resumes previously set speed. LeeBoy 8520C Conveyor Paver 3-11...
  • Page 46 Component Location NOTES 3-12 LeeBoy 8520C Conveyor Paver...

  • Page 47: Operation

    LEEBOY MODEL 8520C CONVEYOR PAVER Section 4 OPERATION OPERATION Page Operation ........4-1 Receiving the Machine .
  • Page 48 Blade Light ......4-45 Magnetic Cup Holder ......4-46 LeeBoy 8520C Conveyor Paver...

  • Page 49: Receiving The Machine

    Hopper Lock Valves The hopper cylinder valves (one on each side) can be The LeeBoy Model 8520C Conveyor Paver offers the used to lock the hopper wings when they are open or latest technology to deliver asphalt more evenly and closed.

  • Page 50: Start-Up Procedure

    E-Stop but- system automatically starts the Thaw Control Mode and ton. turns on the DEF pump, tank and tube heaters. Engine maximum torque may be limited to protect the DEF injector. LeeBoy 8520C Conveyor Paver...

  • Page 51: Dpf Regeneration (Regen)

    • Grade of engine oil. • Pressing the Set Points button navigates to the Set Point and Throttle Speed screen. (Page 4-6) • Grade of diesel fuel. • Use of additives. • Mileage. • Wear of other components. LeeBoy 8520C Conveyor Paver...

  • Page 52: Soft Key Buttons

    DEF level, DEF quality, or SCR system tampering. Tampering includes any sensor or NOTE: Some icons may not be present on your controller errors of the SCR system. model. Complete DEF alerts and warning screens are described on the following pages. LeeBoy 8520C Conveyor Paver...

  • Page 53: Set Points And Throttle Speed

    RPMs), PAVE (1900 RPMs), and TRAVEL (2200 RPMs). (Figure 4-5) Figure 4-6. Engine Throttle Speeds Screen with Generator ON Figure 4-5. Engine Throttle Speeds Screen 1 - IDLE (1300 RPMs) 2 - PAVE (1900 RPMs) 3 - TRAVEL (2200 RPMs) LeeBoy 8520C Conveyor Paver...

  • Page 54: Def Info

    SCR components. NEVER disconnect battery until the purge cycle has completed to prevent serious dam- age to components in the SCR system. Figure 4-8. DEF Info Error Screen LeeBoy 8520C Conveyor Paver...
  • Page 55 (center button) to exit and return to main screen. Figure 4-12. DEF Info Low Screen Figure 4-10. DEF Info Thaw Mode Screen LeeBoy 8520C Conveyor Paver If the level drops to 5 percent (empty), the warning DEF Level Low DEF Level Low...
  • Page 56 Figure 4-14. DEF Temperature >140° Alert Message If the fluid temperature reaches 120° F, a diagnostic message appears, instructing the operator to fill the DEF tank to lower the temperature. (Figure 4-13) Figure 4-13. DEF Temperature >120° Alert Message 4-10 LeeBoy 8520C Conveyor Paver...
  • Page 57 DEF Info screen for complete details. (Figure 4-17) Contact your authorized dealer for service immediately. Press Main Screen (center button) to exit and return to main screen. Figure 4-17. DEF Info Temperature Screen LeeBoy 8520C Conveyor Paver 4-11...

  • Page 58: Main Menu Screen

    The Main Menu choices on the first screen are: • Gauge (Default Screen) • Diagnostics • System Info • Lamp Info Figure 4-19. Main Menu - Second Screen Figure 4-18. Main Menu - First Screen 4-12 LeeBoy 8520C Conveyor Paver...

  • Page 59: Diagnostics

    This can help correlate recent machine activity with the faults that have been recorded. Figure 4-22. Application and Con- figuration Information Screen LeeBoy 8520C Conveyor Paver 4-13...

  • Page 60: Lamp Info

    Figure 4-25. Machine Inhibit- ing DPF Regeneration Screen If the operator chooses to perform a parked regen- eration, the message screen below appears. (Figure 4-26) See Pages 4-21 to 4-23 to perform a parked regeneration. 4-14 LeeBoy 8520C Conveyor Paver...
  • Page 61 DEF tank level icon. The icon changes color with the (Figure 4-29) Engine output is adversely affected DEF fluid level. A WHITE icon indicates the DEF level is and damage may result! normal. (Figure 4-27) Figure 4-27. DEF Level Screen LeeBoy 8520C Conveyor Paver 4-15...

  • Page 62: User Settings

    UP ( ) or DOWN ( ) soft keys to make changes. NOTE: A reboot is required for changes to the Date Setting to take effect. Figure 4-30. User Settings Screen Navigation 4-16 LeeBoy 8520C Conveyor Paver...

  • Page 63: Dpf Commands

    Figure 4-33. Disable (Inhibit) Regen Screen NOTE: The ability to inhibit (disable) regeneration is only possible at DPF Levels 1 and 2. (See DPF Levels, Pages 4-18 to 4-20) Figure 4-32. Regen Alert Message Pop-Up Screen LeeBoy 8520C Conveyor Paver 4-17...
  • Page 64 The DPF system may become Figure 4-34. Enable (Uninhibit) Regen Screen damaged and require replacement. Therefore, per- The soot level will continue to rise while the regen forming regeneration BEFORE reaching Level 4 is imperative to preventing costly repair. 4-18 LeeBoy 8520C Conveyor Paver...
  • Page 65 RPMs and/or load to allow the DPF to automatically regenerate. This only applies at DPF Level 1 and 2. Figure 4-38. Secondary Regen Level 2 Message LeeBoy 8520C Conveyor Paver 4-19...
  • Page 66 Figure 4-39. Regen Level 3 Warning technician. IMMEDIATELY take the machine to a safe location, shut down, and contact your authorized dealer. (Figure 4-41) Regen Level 4: Urgent: Engine output limited. DPF Figure 4-41. Secondary Regen Level 5 Warning 4-20 LeeBoy 8520C Conveyor Paver...

  • Page 67: Perform Parked Regeneration

    During regeneration, EXHAUST TEM- PERATURES WILL BE EXTREMELY HIGH. BE SURE EXHAUST WILL NOT COME INTO CONTACT WITH ANY COMBUSTIBLE MATERIALS. Continue to monitor surrounding areas during the process. If unsafe conditions develop, shut the unit off immediately. LeeBoy 8520C Conveyor Paver 4-21...
  • Page 68 NOT move machine out of park or neutral. DO NOT touch the accelerator pedal/lever. DO NOT turn the engine off or stop the regeneration process. Figure 4-44. DPF (First) Notification Screen Figure 4-46. Third DPF Notification Screen 4-22 LeeBoy 8520C Conveyor Paver...
  • Page 69 Figure 4-48. Fourth DPF Request Regen Screen DO NOT ATTEMPT TO OPERATE THE UNIT, CHANGE ENGINE RPM OR MOVE FROM PARK/NEUTRAL WHILE REGEN IS OCCURRING. This will abort the Regeneration process and require you to start the process over. LeeBoy 8520C Conveyor Paver 4-23...

  • Page 70: Status And Warning Alert Icons

    REGEN cycle to warn of high exhaust temperatures. This lamp will turn off when normal operating temperatures are reached after the REGEN cycle. Be sure engine exhaust is away from any potentially combus- tible materials when this warning icon is illuminated. 4-24 LeeBoy 8520C Conveyor Paver...

  • Page 71: Plus One Controller

    A complete list of fault codes with corrective action messages are shown in Section 5, Troubleshooting. Plus One Light Figure 4-51. Driving the 8520C Driving the Paver The dual operator platforms allow easy and convenient access for controls of most paver functions. Controls Figure 4-50.

  • Page 72: Activate/Deactivate Operator Control Station

    Run/Stop (on the Steering and Speed Control Box) to the STOP position. Figure 4-52. Steering and Speed Control Box 1 - Left and Right Joysticks 2 - Joystick Collar 3 - RUN/STOP Switch 4-26 LeeBoy 8520C Conveyor Paver...

  • Page 73: Paver Operation

    There is a spray down system on both sides of the When using solvents and release Leeboy 8520C paver for your convenience. The wand agents, DO NOT allow cleaning solvent to run onto is conveniently located on each side of the operator’s the ground.

  • Page 74: Heating The Screed

    To operate the electric screed heating system: cool between loads. Start the paver and idle until the engine reaches The LeeBoy 8520C Conveyor Paver is equipped with normal operating temperature. the Legend 815HD (heavy duty) electric heat system to heat the screed and extensions. A belt-driven generator 2.

  • Page 75: Hopper Wings

    Under Auger Material Cut-Offs to the screed. The 8520C paver offers a unique feature for paving To operate the hopper wings: professionals. The operator can also raise each wing individually while paving.

  • Page 76: Conveyors

    Asphalt in the conveyors can fill tracks Left/Right Cut-O and cause damage to the machine. To prevent flight chains from sticking inside the conveyor Figure 4-62. Left and Right Cut-Off Switches pans, lubricate them daily for maximum operational efficiency. 4-30 LeeBoy 8520C Conveyor Paver...

  • Page 77: Tow Point

    5. Use the Thicker/Thinner switch on both sides of the Figure 4-65. Screed Extension Components control panel to adjust mat thickness as you pave. 6. While paving, refer to both gauges to make minor screed adjustments using the tow point. LeeBoy 8520C Conveyor Paver 4-31...
  • Page 78 This will allow the endgate to set itself to the grade. (Figure 4-68) NOTE: Never allow the endgate to carry the weight of the screed to prevent uneven compaction. Left Right Screed Lift/Float Screed Extension Screed Extension Figure 4-68. Screed Switches 4-32 LeeBoy 8520C Conveyor Paver...

  • Page 79: Sonic Auger Sensor

    Turning counterclockwise decreases material height. • When the material height moves into the sonic range, the auger speed will slow down proportionately and turn off. It will turn back on when the material level drops. LeeBoy 8520C Conveyor Paver 4-33...

  • Page 80: Starting To Pave

    Scraper Figure 4-73. Paving a Parking Lot Starting to Pave The LeeBoy 8520C Conveyor Paver provides superior paving for driveways, small to large parking lots, and secondary roads. The paver is equipped with electric Bolt Slots Bolt Slots and manual thickness controls, and can be operated from either side of the operator platform.

  • Page 81: Basic Paving

    6. Turn the left and right conveyor switches to the AUTO position. When the material begins to discharge from under the screed, set the screed lift switch to the FLOAT position. LeeBoy 8520C Conveyor Paver 4-35...

  • Page 82: Setting The Crown

    Example: The trailing edge crown is 0 and the leading edge crown is 1/8 inch. There will not be any crown in the mat, but the material flow under the screed plate will be improved. Gauge Figure 4-78. Crown Adjustment 4-36 LeeBoy 8520C Conveyor Paver...

  • Page 83: Mat Texture Adjustment

    NOTE: Too much pressure on the back of the screed extension will take the weight off the screed wearplate and cause poor material compac- tion, resulting in a poor finish. LeeBoy 8520C Conveyor Paver 4-37...

  • Page 84: Unloading

    Move paver to base of ramp. Line up tracks with the ramp. 2. BEFORE moving the machine, ensure: • The screed position is UP. • Auger extensions are removed. • The extendible screed is IN. • The Under Auger Material Cut-Offs are CLOSED. 4-38 LeeBoy 8520C Conveyor Paver...

  • Page 85: Towing

    NOTE: It may be necessary to adjust the roller guides to the inside of the wheel rims. Figure 4-84. Be sure to push release mechanism back into place and reinstall/tighten bolts on cap when finished moving the paver. LeeBoy 8520C Conveyor Paver 4-39...

  • Page 86: Rubber Track Option

    Berm Screed Extension Attachment Attachment The LeeBoy 8520C paver is equipped with poly-pad tracks, but a rubber track option is also available. The Berm Screed Extension Attachment (HD Screed only) allows you to adjust the last one foot of each extension to pave up to a four-inch roll-up curb.

  • Page 87: Roll-Up Curb Attachments

    • Push switch DOWN for decreased negaive crown (valley). Temperature Set Point (Decrease Heat) Temperature Select (Increase Heat) Power Crown Switch Figure 4-88. Power Crown Switch Figure 4-89. Automatic Temperature Control LeeBoy 8520C Conveyor Paver 4-41...

  • Page 88: Topcon® Sonic And Dual Grade Control

    NOTE: This is the valve offset setting, which varies from paver to paver. Make a note of this num- (Shown with Cap) ber on the Notes page provided in this manual Figure 4-90. Connector Cables for future reference. 4-42 LeeBoy 8520C Conveyor Paver...

  • Page 89: Horizontal Flight Screws

    It cannot be emphasized enough that the Figure 4-92. Horizontal Flight Screw paver needs to be on level ground for correct instal- lation and operation. LeeBoy 8520C Conveyor Paver 4-43...

  • Page 90: Tool Rack

    (Figure 4-94) The tool rack is mounted on the back of the paver for screed operator convenience. See your authorized dealer for purchase. Figure 4-94. Tool Rack 4-44 LeeBoy 8520C Conveyor Paver...

  • Page 91: Heated End Gate

    The light wings are mounted on a 15-foot tripod that can also be adjusted for height, then easily retracted for storage. See your authorized dealer for purchase. Figure 4-97. Blade Light Option LeeBoy 8520C Conveyor Paver 4-45...

  • Page 92: Magnetic Cup Holder

    Holder Holder Your paver is shipped with two magnetic cup holders, but you can purchase more. (Figure 4-98) See your authorized dealer for details. Ask for Part Number 1020521. Figure 4-98. Mag- netic Cup Holder 4-46 LeeBoy 8520C Conveyor Paver...
  • Page 93 LeeBoy Model 8510C Conveyor Paver LeeBoy Model 8510C Conveyor Paver Section 5 MAINTENANCE MAINTENANCE Page Maintenance ....... . . 5-1 Maintenance Schedule .
  • Page 94 Torque Hub ......5-35 Replace Tracks ......5-36 LeeBoy 8520C Conveyor Paver...
  • Page 95 PV485 Troubleshooting ..... . . 5-64 Plus One Controller ......5-66 LeeBoy 8520C Conveyor Paver...

  • Page 96: Maintenance Schedule

    Before performing any maintenance procedures on damage or possible injury. the LeeBoy Model 8520C Conveyor Paver, review the When performing any routine safety information in Section 1. Refer to the Engine maintenance, always include the previous routine Operator’s Manual accompanying your paver for more...

  • Page 97: Accessing Components

    Raise and Lower Engine Hood 5 5 5 Accessing the radiator and other engine components is simple and convenient on the 8520C paver. The engine hood pivots forward for convenient access to the radiator and other engine service points. (Figure 5-1) Access doors on each side of the paver also provide easy access for servicing various components.

  • Page 98: Raise And Lower The Conveyor

    Be sure to return the tool to its mount after each use. Figure 5-6. Insert Hopper Wing Fold-Out Tool Figure 5-5. Hopper Wing Fold-Out Tool LeeBoy 8520C Conveyor Paver...
  • Page 99 (See Torque chart in Section 2.) 8. Return the hopper wing fold-out tool back to its mount on the right engine access panel door and reinsert the cotter pin to secure it. LeeBoy 8520C Conveyor Paver...

  • Page 100: Routine Maintenance

    2. Raise conveyors and place safety prop into position. (Pages 5-6 and 5-7) Clean any asphalt material off all flat surfaces. Remove any debris from screed and check for leaks. LeeBoy 8520C Conveyor Paver...

  • Page 101: Every 100 Hours Or Monthly Maintenance

    5. Replace fuel filter. (Page 5-23) 6. Clean fuel water separator. (Page 5-24) Change the hydraulic oil and filter. (Page 5-25) 8. Perform previous routine maintenance and any other engine preventive maintenance described in the Engine Operator’s Manual. LeeBoy 8520C Conveyor Paver...

  • Page 102: Lubrication

    U-joints (both sides). Weekly Augers (one centralized grease point lubricates auger components). Daily Conveyor chains (one on each side of each conveyor). Daily Spray all parts of paver that come into contact with asphalt. Daily 5-10 LeeBoy 8520C Conveyor Paver...

  • Page 103: Daily Lubrication

    (beneath the operator platform). When you pump grease into the central point, valves distribute the grease evenly to the auger bearings and other moving parts. Use Shell Avania EP Grease 2 or equivalent. LeeBoy 8520C Conveyor Paver 5-11...

  • Page 104: Weekly Lubrication

    Use a mechanic creeper or back the Conveyor paver up onto ramps to access the conveyor pivot from the undercarriage. Pivot Lock the screed before greasing the conveyor pivot to prevent movement that could result in injury. 5-12 LeeBoy 8520C Conveyor Paver...

  • Page 105: Torque Hub Lubrication

    • Excessive run-out of the front sprockets: • Check to verify sprocket run-out pin on the shaft. Run-out should not exceed .030 inches. • If excessive, replace chain or sprocket. LeeBoy 8520C Conveyor Paver 5-13...
  • Page 106 12. Start the engine to lower the conveyor. loosening the 4 nuts underneath. (Figure 5-11) 13. Push hopper wings back into position and reinstall Idler Mount Bolts the four wing bolts on each side. Figure 5-11. Idler Mount Bolts 5-14 LeeBoy 8520C Conveyor Paver...

  • Page 107: Conveyor Drive Chains

    4. Turn the chain adjuster to loosen or tighten the chain, leaving approximately 1/4-inch of slack. DO NOT overtighten. 5. Retighten jam nuts. Tension 6. Repeat steps on the other side. Adjusters Figure 5-14. Auger Drive Chain Bolts LeeBoy 8520C Conveyor Paver 5-15...

  • Page 108: Screed Extension Top Guide Adjustment

    These adjustment panel. (Pages 3-6 to 3-7) should only be performed by an authorized LeeBoy dealer. Work not performed by an authorized dealer 2. Loosen the top guide and hold-down bolts. (Figure can damage machine and void the warranty.

  • Page 109: Engine Maintenance

    Check Engine Lubrication Oil The engine lubrication oil must be kept at a level above The LeeBoy 8520C Conveyor Paver features the latest the ADD mark, but not above the FULL mark, on the in engine technology. Tier 4 engines comply with emis- engine lubrication oil dipstick.

  • Page 110: Change Engine Oil And Filter

    5. Wipe inside the oil filter head using a clean, lint-free cloth. 6. Rub a little oil on the rubber gasket area of the new filter element. Install the new filter element onto the filter head. Carefully tighten the filter (by hand only). 5-18 LeeBoy 8520C Conveyor Paver...

  • Page 111: Change Air Filter

    Alternator NOTE: The air filter elements should be replaced Bolts every 250 service hours of normal paver operation, but more often if the paver is operated in severe conditions. Belt Figure 5-19. Engine Belt LeeBoy 8520C Conveyor Paver 5-19...

  • Page 112: Change Oil Separator Element

    DO NOT pressure wash or steam 4. Insert a new filter element and gasket. clean this unit to avoid damaging the components. Use compressed air to remove any loose debris. 5. Reattach the cover cap to the oil separator body. 5-20 LeeBoy 8520C Conveyor Paver...

  • Page 113: Def (Diesel Exhaust Fluid)

    DEF, if the smell of ammonia is present, the DEF fluid has started to break down and LeeBoy recommends it be changed or discarded. If DEF is stored or used above 86°F, the DEF life will be Tank reduced.

  • Page 114: Dpf Service

    To reduce the amount of soot and maximize DPF efficiency, use API-CJ4 (or ACEA-E9 European equivalent) engine oil. Running the engine at 1600 RPMs will also provide more efficient operation and allow automatic regeneration more efficiently while paving. 5-22 LeeBoy 8520C Conveyor Paver...

  • Page 115: Replace Radiator Hoses

    (Figure 5-25) DO NOT change the fuel filter while the engine is running. DO NOT smoke or change fuel filter near open flames as diesel fuel is highly combustible. Be careful not to spill fuel. LeeBoy 8520C Conveyor Paver 5-23...

  • Page 116: Fuel Water Separator

    3. Reinsert and tighten. 10. Start the engine and check for any fuel leaks. Explosion Hazard! Stop the engine immediately if any fuel leakage is noted. DO NOT start the engine until the leak has been corrected. 5-24 LeeBoy 8520C Conveyor Paver...

  • Page 117: Hydraulic System

    Maintenance Hydraulic System reservoir. Leeboy uses a leak-detection dye that Check Hydraulic Oil Check Hydraulic Oil may turn the hydraulic oil a slight yellow tint. The hydraulic motors and hydraulic cylinders use the same hydraulic oil reservoir and hydraulic oil supply.

  • Page 118: Electrical System

    If battery fluid contacts the eyes or skin, immediately flush with clean water and obtain prompt medical treatment. Keep sparks and flames away from the batteries as electrolyte gas is highly flammable. 5-26 LeeBoy 8520C Conveyor Paver...

  • Page 119: Battery Servicing

    • Always connect a booster battery in the proper 6. Check vent cap breather openings to ensure they polarity: Negative (-) to negative (-) and positive (+) to are clear. positive (+). LeeBoy 8520C Conveyor Paver 5-27...

  • Page 120: Fuse Panel

    6 - Automatic/Manual Power Toggle Button 7 - Toggle for Left/Right Endgates 8 - Wire Junction Block Figure 5-31. Fuse Panel 9 - Manual Mode Timer TopCon controller system if equipped with this 10 - Heat ON Button option. 5-28 LeeBoy 8520C Conveyor Paver...

  • Page 121: Element Resistance Testing

    If the element is functioning correctly, you should read a resistance between the connector pins when testing. A faulty element will show high resistance, indicating a bad element. LeeBoy 8520C Conveyor Paver 5-29...

  • Page 122: Heating Elements

    Hz meter (valve should be 60 - 63 Hz. 3. If the voltage is still low, contact your authorized LeeBoy dealer for generator speed tuning (see next section). 5-30 LeeBoy 8520C Conveyor Paver...

  • Page 123: Generator Capacitor Replacement

    Examine the routing of the harness and ensure it is not subjected to excessive movement, which often causes broken wiring. LeeBoy 8520C Conveyor Paver 5-31...

  • Page 124: Dielectric Grease

    Figure 5-38. Incorrect Application of Dielectric Figure 5-37. Correct Application of Dielectric Grease Grease 5-32 LeeBoy 8520C Conveyor Paver...

  • Page 125: Replacement Procedures

    3. Label, plug and cap the hoses. The gear pump assemblies are very heavy and must be properly supported with a sling before continuing the following steps. DO NOT loosen mounting bolts unless the pump is sufficiently supported. LeeBoy 8520C Conveyor Paver 5-33...

  • Page 126: Two-Speed Hydraulic Motors

    (Refer to Torque Tables in Section 2.) 8. Reconnect hydraulic hoses. 9. Start the engine and let machine idle for 10 minutes to work air out of the hydraulic system. 10. Check for any leaks. 5-34 LeeBoy 8520C Conveyor Paver...

  • Page 127: Torque Hub

    Once all system connections are made, the motor should be run for 15 - 30 minutes at no-load and half- speed to bleed air from the hydraulic system. Bolts (16) Figure 5-44. Torque Hub LeeBoy 8520C Conveyor Paver 5-35...

  • Page 128: Replace Tracks

    11. Insert pin and weld keepers at end of pin. 12. Screw track tension manifold relief cartridge back into place and check hydraulic oil level. Add more if needed. 5-36 LeeBoy 8520C Conveyor Paver...

  • Page 129: Rubber Track (Option)

    Lower the undercarriage for undercarriage at track tension manifold. replacing above components, except rollers. 5. Cap and plug all hoses. NOTE: Remove generator cord at generator if removing left undercarriage (electric heat screed only). LeeBoy 8520C Conveyor Paver 5-37...

  • Page 130: Front Idler

    4. Install idler, ensuring cylinder and clip pin are aligned properly. NOTE: If equipped with poly or steel tracks, follow Steps 8 - 11 above. Front Idler Clevis Pin Figure 5-46. Remove Clevis Pin to Release Front Idler 5-38 LeeBoy 8520C Conveyor Paver...

  • Page 131: Track Rollers

    Drive paver forward to rotate track onto top center. of the sprocket. 12. Place master pin back in track and place thread- locking adhesive on bolts. 13. Tighten relief cartridge in the manifold. LeeBoy 8520C Conveyor Paver 5-39...

  • Page 132: Rear Conveyor Shaft, Bearings And Sprockets

    5. Secure with four bolts. 6. Reconnect hydraulic hoses to motor. Adjuster Check for leaks. Bolts Chain Conveyor Motors Sprocket Shaft (Inside Tubing) Main Chains Main Conveyor Chains Figure 5-47. Conveyor Components 5-40 LeeBoy 8520C Conveyor Paver...

  • Page 133: Auger Inner Bearings

    15. Operate augers to ensure proper function. NOTE: Auger chains can be lubricated each day by Rear spraying oil or chain lube through the slots Auger where auger motor is adjusted. Cover Figure 5-50. Rear Auger Cover (Side View) LeeBoy 8520C Conveyor Paver 5-41...

  • Page 134: Auger End Mounts

    19. Reconnect the hydraulic hoses and check for leaks. 6. Loosen auger tension adjusters. Loosen the two bolts securing the auger motor mounting brackets. 8. Loosen the auger chains by sliding the auger motors out from the backside. 5-42 LeeBoy 8520C Conveyor Paver...

  • Page 135: Quick Change Augers

    6. Disconnect (and cap) the lubrication hoses from the grease points on each side of the lower auger cover, and grease hose on the side for auger replacement. (Figure 5-55) LeeBoy 8520C Conveyor Paver 5-43...

  • Page 136: Under Auger Material Cut-Offs

    13. Reinstall auger cover and reconnect grease hoses. (Figures 5-55 and 5-56 on the previous page.) 14. Start the engine and idle for a few minutes, then turn on the auger and check for proper operation. 5-44 LeeBoy 8520C Conveyor Paver...

  • Page 137: Main Screed Wear Plate

    2) starting inside, then moving outward, by rotating from the left to the right side to keep the screed relaxed. 16. Reinstall the screed covers in reverse order, then the walk boards. Figure 5-60. Inner Screed Element Covers LeeBoy 8520C Conveyor Paver 5-45...

  • Page 138: Screed Extension Wear Plate

    Reinstall the endgate and tilt screw. NOTE: If equipped with electric screed heat option, remove all wiring and heating elements. AOA Adjuster Adjuster Pivot Pin Shoulder Bolt and Nut Figure 5-62. Wear Plate Replacement 5-46 LeeBoy 8520C Conveyor Paver...

  • Page 139: Hopper Wing Cylinders

    Hydraulic oil that is contaminated must be drained, the filter elements replaced and the hydraulic tank refilled. Failure to perform this maintenance procedure if needed could result in premature failure of the pumps or motors. LeeBoy 8520C Conveyor Paver 5-47...
  • Page 140 Place a “No Water” sign on the pressure cap. 12. Disconnect battery, adjust the electrolyte level, and recharge it. Store battery inside in a cool, dry place. Ensure breakers are in the OFF position. 5-48 LeeBoy 8520C Conveyor Paver...
  • Page 141 DO NOT MAKE MODIFICATIONS TO THE MACHINE. ONLY weld if needed for repair purposes. Weldment modifications to the machine can void your warranty. LeeBoy 8520C Conveyor Paver 5-49...

  • Page 142: Troubleshooting

    3. If adjustment is needed, locate the pressure- reducing valve on left side of main manifold. 4. Remove valve cap with an allen wrench. 5. Adjust the pressure-reducing valve clockwise for more tension or counterclockwise for less tension. 5-50 LeeBoy 8520C Conveyor Paver...

  • Page 143: Auger And Conveyor Chain Tension Adjustment

    0.4 - 0.6 0.6 - 0.9 1.0 - 1.5 1.4 - 2.1 2.0 - 3.0 45° To Vertical (5 - 8) (10 - 15) (15 - 23) (25 - 38) (36 - 53) (51 - 76) LeeBoy 8520C Conveyor Paver 5-51...

  • Page 144: Spraydown Pump

    • Retighten the bleeder valve. If the overload reaches a dangerous level, the red NOTE: Change filter as needed. LED will become solid and you must switch the power off and start the pump again. 5-52 LeeBoy 8520C Conveyor Paver...

  • Page 145: Troubleshooting Chart

    Maintenance Troubleshooting Chart The troubleshooting chart below identifies the most Contact your authorized LeeBoy dealer for assistance, common symptoms of mechanical problems. Fault service or repair. codes are also shown on the PV480 Digital Display unit on the Operator Control Panel.
  • Page 146 Check oil cooler and thermostat. Low level in hydraulic tank. Refill to proper level. Clogged filters. Replace filters. Hydraulic pump cavitation or lost power. Suction hose loose. Retighten. Charge pump worn. Rebuild or replace charge pump. 5-54 LeeBoy 8520C Conveyor Paver...
  • Page 147 Ensure generator is “spinning.” Check voltage and Generator malfunction. to pave. frequency. Rebuild or replace if needed. Elements have been tested, Faulty element wiring. Inspect and test element wiring. but the breaker still trips. LeeBoy 8520C Conveyor Paver 5-55...

  • Page 148: Pv480 Diagnostic Trouble Code (Dtc) Chart

    High with high altitude usage. Engine power drops.) Diagnostic counter = zero Barometric pressure (Default value is set in consideration Barometric voltage 1.6V or less. sensor error: Low with high altitude usage. Engine power drops.) 5-56 LeeBoy 8520C Conveyor Paver...
  • Page 149 (Not monitored during cranking.) Open circuit or +B short circuit of Intake air temperature sensor/harness. Intake air tempera- Diagnostic counter = zero built-in MAF sensor: High ture built-in MAF sensor voltage: 4.9V or more. LeeBoy 8520C Conveyor Paver 5-57...
  • Page 150 Engine vibration increases slightly. Open circuit of harness or injector coil. Open circuit of harness/ Engine vibration increases. Injectors Key switch turn OFF. coil in 1st cylinder injector. that have no error are operated. 5-58 LeeBoy 8520C Conveyor Paver...
  • Page 151 1319° F (715° C). Engine stops. Inhibit Under 572° F (300° C) and key switch 3242 temperature sensor 1: starter relay activation until exhaust turn OFF. High temperatures reduces down to 572° F (300° C). LeeBoy 8520C Conveyor Paver 5-59...
  • Page 152 STRONGLY recommend operator to level. Regeneration Level = 5. stop engine promptly. Must be reset by Kubota service tool. PM accumulation more than trigger 3701 Excessive PM 3. Diagnostic counter = 0 level. Regeneration Level = 3. 5-60 LeeBoy 8520C Conveyor Paver...
  • Page 153 During wrong duty feedback, activation of restoration will repeat 30 times. If 523536 EGR feedback error. Diagnostic counter = zero the restoration was not successfully completed, it will be judged as a feed- back error. EGR stops. LeeBoy 8520C Conveyor Paver 5-61...
  • Page 154 EGR actuator open error signal 523574 EGR actuator open circuit. Key switch turn OFF. received via CAN. EGR stops. EGR actuator valve stuck error 523575 EGR actuator valve stuck. Key switch turn OFF. received via CAN. EGR stops. 5-62 LeeBoy 8520C Conveyor Paver...
  • Page 155 CAN ETC5 frame time-out error. Key switch turn OFF. frame error. No request to “TSC1 buffer” continues 523596 CAN TSC1 frame error. three times after over-ride control Diagnostic counter = zero request (other than 0x00). LeeBoy 8520C Conveyor Paver 5-63...

  • Page 156: Pv485 Troubleshooting

    3. Inspect the terminals in positions 14 (green) and 26 (yellow) for the CANbus communication. 4. If terminals are properly seated, carefully “unlock” the red retaining clip and slide away from the wires. (Figure 5-71) Clip Figure 5-71. PV485 Main Connector 5-64 LeeBoy 8520C Conveyor Paver...
  • Page 157 OR checking for +12VDC on will not operate. each pin on the back of the fuse. If none of these procedures correct the problem, con- tact your authorized LeeBoy dealer for assistance. LeeBoy 8520C Conveyor Paver 5-65...

  • Page 158: Plus One Controller

    • There is only one steering control box present. • The fault happens in the steering control box that has control (Run/Stop switch in the RUN position). • The fault occurs when neither steering control box is in control. 5-66 LeeBoy 8520C Conveyor Paver...
  • Page 160 ST Engineering LeeBoy, Inc., dba LeeBoy 500 Lincoln County Parkway Ext. Lincolnton, North Carolina 28092 Phone: (704) 966-3300 - Fax Sales: (704) 483-5802 Scan QR Code to download and view this manual. www.LeeBoy.com Printed in the U.S.A.

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