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TABLE OF CONTENTS
TASK PAGE NO.
B-1
Highway Class Paver/Finishers Control Systems
ALPHABETICAL INDEX
TASK PAGE NO.
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Control Systems Highway Class Paver/Finishers
B-3
Highway Class Paver/Finishers Control Systems
CONTROL SYSTEMS THEORY The PF-5500 and PF-5510 tilting control consoles are
located in front of the operator’s seats. The control
OF OPERATION console contains all of the following controls under
lockable cover; main power/engine kill switch, starter
The highway class paver/finisher employs a variety of button, throttle switch, screed switch, parking brake
controls for the operation of the machine. The major switch, parking brake light, vibrator switch, auger
controls are described below. switch, L.H. and R.H. conveyor switches, L.H. and
R.H. flowgate switches, hopper switch, horn button,
The control stations are located on both sides of the engine tachometer/travel speed gauge L.H. console
machine to give the operator a choice of operating only), oil pressure gauge, water temperature gauge,
position based on direction of travel, obstacles in the hydraulic oil temperature gauge, voltage gauge, fuel
area and location of steering reference such as gauge (R.H. console only), and truck hitch switch if
centerline, joint to be matched, curb, etc. machine is equipped with an optional truck hitch.
Below the control console, the control console
pedestal contains the console tilt adjusting knob,
transmission shift knob (PF-5510 only) and the motor
shift knob (PF-5500 only).
2741-10
TYPICAL CONTROL STATION
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Control Systems Highway Class Paver/Finishers
2741-5
2728-34
BK-76
BRAKE/SHIFT/TOW VALVE AUTOMATIC LEVEL CONTROL
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Highway Class Paver/Finishers Control Systems
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Control Systems Highway Class Paver/Finishers
TROUBLESHOOTING
The troubleshooting guides in this section list the common malfunctions which may be found
during the operation or maintenance of the machine. You should perform the test/inspections
and corrective actions in the sequence listed.
This manual cannot list all malfunctions that may occur, nor all tests or inspection and correc-
tive actions. If a malfunction is not listed or it is not corrected by the listed corrective actions,
notify your supervisor.
• Question the operator if possible to obtain any information that might help determine the
cause of the problem.
• Never overlook the chance that a problem could be of simple origin. The problem could be
corrected with minor adjustments.
• Use test instruments or gauges to help you determine and isolate problems.
• Always isolate the system where the malfunction occurs and then locate the defective
component.
TROUBLESHOOTING GUIDE
ENGINE CRANKS BUT WILL NOT START
(All main switches ON)
No fuel in tank. 1. Operator error. 1. Check fuel level in tank. Fill tank.
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Highway Class Paver/Finishers Control Systems
ENGINE CRANKS BUT WILL NOT START (All main switches ON)
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Control Systems Highway Class Paver/Finishers
Traction lever(s) not 1. Operator error. 1. Check that both traction control levers are both
in neutral. in neutral position. Reposition levers.
Poor starter motor 5. Lack of 5. Check starter connections. Clean and tighten.
connections. maintenance.
Open electrical 6. Loose 6. Check for wire off any terminal in circuit.
circuit. connection. Reconnect.
Faulty “power” relay 10. Overheated or 10. Check voltage and continuity. Replace.
(inside electrical shorted.
junction box).
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Highway Class Paver/Finishers Control Systems
No hydraulic fluid in 2. Leak or lack of 2. Check hydraulic tank dip stick. Fill.
tank maintenance.
Clutch not engaged 3. Operator error. 3. Check clutch lever. Engage or adjust clutch.
Open traction (shift) 5. Loose 5. Check for wire off any terminal in circuit.
electrical circuit connection. Reconnect.
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Control Systems Highway Class Paver/Finishers
Equal traction lever 1. Various 1. Check linkage from levers to traction pumps.
movement does not possibilities. Adjust.
produce straight Check both L.H. and R.H. traction pumps for
travel. equal charge pressure. Adjust.
Check either L.H. or R.H. brake (within torque
hub) not released. Repair or replace.
Check operation of positive traction valves.
Replace coil(s). Clean orifice(s). Replace.
Check both L.H. and R.H. traction motor in
same shift position. Replace solenoid.
Check shaft switch position. Reposition.
Replace.
Faulty traction 2. Bad coil/valve 2. Check both L.H. and R.H. traction motor in
motor shift solenoid stuck. same shift position. Replace coil. Replace sole-
noid.
Faulty shift switch 3. Worn or faulty. 3. Check shift switch position. Reposition. Replace.
(on operator’s
console)
Faulty planetary 5. Worn or 5. Check either L.H. or R.H. brake (within torque
torque hub damaged. hub) not released. Repair or replace.
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Highway Class Paver/Finishers Control Systems
Faulty pivot steer 2. Bad coil/valve 2. Check voltage. Replace coil. Replace solenoid.
solenoid valve (on stuck.
traction pump(s))
Faulty positive 3. Bad coil/valve 3. Check operation. Replace coil. Clean orifice.
traction valve(s) stuck/orifice Replace.
clogged.
Faulty traction 4. Bad coil/valve 4. Check both L.H. and R.H. traction motor in shift
motor shift solenoid stuck. position. Replace coil. Replace solenoid.
Faulty shift switch 5. Worn or faulty. 5. Check shift switch position. Reposition. Replace.
(on operator’s
console)
Faulty planetary 7. Worn or 7. Replace either L.H. or R.H. brake (within torque
torque hub damaged. hub) not released. Repair or replace.
Steering linkage 9. Worn or 9. Check tie rods (below hopper). Straighten rods.
bent or worn damaged. Adjust or replace rod ends.
Faulty steering units 10. Worn seals. 10. Try opposite operator’s console. Repair or replace.
Faulty steering 11. System 11. Check all hoses, tubes and fittings. Repair or
hydraulic circuit leaking. replace.
Faulty steering 12. Worn seals. 12. Check for piston leak-by with cylinder fully
cylinders extended and retracted and alternate hoses dis-
connected. Replace O-ring seals.
Worn king pin 13. Excessive 13. Check for free pivot movement of wheels with
bearings wear. steering cylinders disconnected. Replace bearings.
Worn wheel spindle 14. Excessive 14. Check for free, smooth rotation of wheels.
bearings wear. Replace bearings.
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Control Systems Highway Class Paver/Finishers
FWA switch is ON 1. Wrong shift 1. Check that transmission shift switch is at “1” or
but bogie wheels switch posi- “2” position and traction lever is pushed
do not turn. tion/bad valve. FORWARD. Check manual override on bypass
valve. Check voltage and continuity of bypass
valve coil. Replace coil.
Open electrical 2. Loose wire 2. Check L.H. and R.H. console plug-in(s) at
circuit. connection. electrical junction box. Engage plug-in(s).
Check for loose connection at any terminal in
circuit. Reconnect.
Faulty “motion” limit 3. Switch worn or 3. Check operation, voltage and continuity. Adjust
switch in L.H. misadjusted. switch. Replace switch.
traction console.
Faulty “motion” 4. Relay bad. 4. Check voltage and continuity. Replace relay.
relay inside
electrical junction
box.
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Highway Class Paver/Finishers Control Systems
Brake does not 1. Switch bad / 1. Check voltage and continuity of switch. Replace
release when clutch slipping. switch. Check clutch adjustment. Adjust clutch.
switch is OFF.
Faulty “brake” relay 3. Relay bad. 3. Check voltage and continuity. Replace relay.
inside electrical
junction box.
Faulty “motion/ 4. Short in circuit 4. Locate short in circuit. Reset breaker. Check
brake” circuit or circuit voltage and continuity. Replace breaker.
breaker inside breaker bad.
electrical junction
box.
Faulty “console” 5. Short in circuit 5. Locate short in circuit. Reset breaker. Check
circuit breaker or circuit voltage and continuity. Replace breaker.
inside electrical breaker bad.
junction box.
Open electrical 6. Loose wire 6. Check L.H. and R.H. console plug-ins at
circuit. connection. electrical junction box. Engage plug-ins. Check
for wire off of any circuit terminal. Reconnect
wires.
Faulty planetary 7. Low oil level or 7. Check fluid level. Refill. Replace clutch packs
torque hub. faulty brakes within torque hub. Replace torque hub.
within torque
hub.
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Control Systems Highway Class Paver/Finishers
Note: Refer to the Electrical Section for additional information concerning electrical components within the
console.
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Highway Class Paver/Finishers Control Systems
2741-10
707-070A
Step 2:
Remove steering unit assembly.
a. Remove the rear cover of the console.
b. Remove bolts (5) and disconnect console
assembly from the pedestal.
c. Disconnect the hydraulic hoses (6) at the base
of the steering unit.
d. Mark, cap and plug all hoses and steering
ports.
2724-11
5
6
2741-10
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Control Systems Highway Class Paver/Finishers
DISASSEMBLY ASSEMBLY
Step 1: Step 1:
Remove operator’s control console. OPTIONAL: If further disassembly of the steering
a. Disconnect wire harness (1) from main unit was required, refer to vendor material for
electrical junction box. assembly.
Step 2:
Install electrical switches, wiring, control console
and/or steering unit by reversing the disassembly
procedures.
1 INSTALLATION
Install the steering console assembly be reversing the
disassembly procedures.
NOTE
Steering column is keyed. Ensure steering
wheel is positioned properly before installing.
2965-14
EQUIPMENT PREPARATION
b. Disconnect steering hydraulic hoses (2). Step 1:
Connect battery or turn battery master disconnect
switch ON.
Step 2:
Check hydraulic tank fluid level. Fill if necessary.
Step 3:
Test steering console.
a. Move blocks away from tires.
b. Start engine.
c. Move machine forward. Turn wheels to the left
and to the right to make sure machine is
steering properly.
2741-5
Step 2:
OPTIONAL: If further disassembly of the steering
unit is required, refer to Appendix B-1 for a list of
available vendor publications.
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Highway Class Paver/Finishers Control Systems
Note: Refer to the Electrical Section for additional information concerning electrical components within the
console.
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Control Systems Highway Class Paver/Finishers
OPERATOR’S CONTROL
CONSOLE (TRACKED)
REMOVAL
Step 1: 3
Disconnect the control box.
a. Remove the control panel mounting screws
(1).
b. Pull the control panel out enough to flip over.
c. Tag and disconnect wires from switches and
buttons.
2724-14
1
ASSEMBLY
Install the electrical switches, wiring and control
console by reversing the disassembly procedures.
INSTALLATION
Install the operator’s console assembly by reversing
the removal procedures.
EQUIPMENT PREPARATION
2965-2
Step 1:
DISASSEMBLY Connect battery or turn battery master disconnect
switch ON.
Step 1:
Remove operator’s control console. Step 2:
a. Disconnect wire harness (2) from main Check operation of control console switches and
electrical junction box. buttons.
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Highway Class Paver/Finishers Control Systems
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Control Systems Highway Class Paver/Finishers
2724-20
Step 3:
Remove control lever assembly (4) from console.
a. Disconnect electrical wire harnesses (5) to
limit switch and Fumes Recovery switch.
1 b. Remove control lever mounting bolts.
c. Lift reverse lockout gate and control lever
assembly out of console.
whcnsl.2
5
2
whcnsl.1
trcnsl.1
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Highway Class Paver/Finishers Control Systems
3
1
1
0960-088
Step 2:
Remove limit switch and actuator (2). (L.H.
console only.)
a. Remove wire assembly (3) to limit switch.
b. Remove switch bracket mounting bolts.
c. Remove switch from assembly.
wlhndl.1 3 2
Step 2:
Remove limit switch (4) and actuator (5). (L.H.
console only.)
a. Remove mounting bolts (6) from limit switch
mounting bracket (7).
b. Remove actuator mounting nut (8).
c. Remove limit switch (4).
6 5 7
6 0960-089
8
4
trcnsl.3
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Control Systems Highway Class Paver/Finishers
Step 3: Step 5:
Lift rear center deck. Remove the traction control cable (8).
a. Loosen the lock nut (9) at rod ends.
Step 4:
Remove the long shaft (4).
a. Remove coupling (5), key and set screw (both
sides).
b. Remove flange bearings (6), if desired.
8
9
1144-013
b. Remove clamps.
c. Remove traction control cable from traction
control pumps (10).
6
whcnsl.2 10
Step 4:
Remove the short shaft (7) (both sides).
a. Remove the flange bearing (both sides).
b. Pull shaft through the lower cam.
5510pmp.1
ASSEMBLY/INSTALLATION
17 Install traction control (wheeled machines) by reversing
disassembly and removal procedures.
7
19 IMPORTANT
The force to move traction levers should be
adjusted to 1 lb. +/- 1/2 lb.
18 BK-73A
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Highway Class Paver/Finishers Control Systems
Step 2: Step 2:
Adjust limit switch (L.H. console only). Test traction control.
IMPORTANT IMPORTANT
In order to start machine, limit switch must be Traction levers should remain in any position
fully extended in notch on cam. they are placed, but move easily when
repositioned.
a. Remove L.H. console reverse-lockout/gate
plate (1). a. Move levers forward and reverse to check
b. Adjust switch actuator shaft length so that the machine movement and neutral position.
roller just touches cam inside notch when b. Adjust friction unit as required.
lever is in neutral position.
c. Verify switch operation: With lever out of NOTE
neutral, engine should start. There is no neutral adjustment on the traction
d. Install L.H. console reverse lockout/gate plate. drive pumps. Neutral adjustment is made by
adjusting the rod ends of the traction control
cables.
2724-20
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Control Systems Highway Class Paver/Finishers
Note: Refer to the Electrical Section for additional information concerning electrical components within the
console.
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Highway Class Paver/Finishers Control Systems
2
trcnsl.1
Step 4:
Disconnect the Fumes Recovery switch (6).
a. Remove the wire clamps.
b. Tag and disconnect wires to switch.
c. Remove switch, if necessary.
2965-4
Step 2:
Remove the nut (3) and disconnect rods from the 6
L.H. and R.H. cross shaft cables (4).
trcnsl.1
4
Step 5:
Remove the traction control console assembly.
a. Remove traction control console mounting
bolts.
b. Lift console off machine.
2965-4
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Control Systems Highway Class Paver/Finishers
DISASSEMBLY Step 3:
Disconnect L.H. and R.H. control cables (5). (L.H.
Step 1: side of machine only.)
Remove rods from cams inside control console. a. Disconnect cable from cross-shafts.
a. Remove nut (1) securing rod to the cams.
b. Remove rods from the control console.
NOTE 5
Do not change length of the rods if machine
has been tracking properly. See “Adjustment”
section if necessary.
2965-5
6
2965-4
Step 2:
Remove control arms.
a. Remove handle screws (2).
b. Remove screws on top panel (3). It is neces-
sary for cover plate to move freely.
c. Push one control arm handle down at a time.
5510p2.tif
d. Remove control arms (4).
e. Remove bearings if desired.
ASSEMBLY/INSTALLATION
2 Install the traction control console (tracked machines)
by reversing the disassembly and removal
procedures.
3
2965-4
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Highway Class Paver/Finishers Control Systems
5510trcns.3
Step 2:
16º
Adjustment of direction-speed (travel) controls.
WARNING
Do not run engine while travel control linkage
is disconnected. Machine could move, caus-
ing property damage, personal injury or
death. 5510pmpcnt.tif
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Control Systems Highway Class Paver/Finishers
5510p2.tif
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Highway Class Paver/Finishers Control Systems
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Control Systems Highway Class Paver/Finishers
2724-14
2724-22
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Highway Class Paver/Finishers Control Systems
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Control Systems Highway Class Paver/Finishers
2 2966-5
Step 3:
Remove Blaw-Kontrol valve(s) if necessary. See
“Valves” on pages D-39 to D-46 of the Hydraulics
module for testing and repair procedures.
1
NOTE
Valves may be tested or repaired in position.
NOTE
Before performing any work on any valve it is
blawkntrl.2
important to clean the exterior of the affected
b. Remove grade sensor (3). valve manifolds of any dirt, etc. to prevent
contamination from entering the hydraulic
system.
10
8
blawkntrl.1 9
Step 2:
Remove side arm cylinder (4).
a. Disconnect hydraulic hoses.
b. Mark, cap and plug hoses and fittings.
c. Remove cotter pins. 5
d. Drive clevis pin out of clevis and base.
NOTE 7
Control valves are located below deck, 6
behind the side arm cylinders on the
transverse bulkhead, L.H. and R.H. sides.
0718-75
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Highway Class Paver/Finishers Control Systems
e. Loosen mounting nut on valve cartridge and c. Replace potentiometer (12) if needed.
rotate the solenoid valve counterclockwise to
remove it from the manifold. Be careful not to
allow contamination to enter the valve cavity.
DISASSEMBLY
Step 1:
Disassemble the grade sensor mounting
assembly.
a. Remove shoe (1) from wand (2).
b. Remove wand from grade sensor (3).
c. Remove grade sensor from mounting tube (4).
d. Remove mounting tube from pivot(5).
e. Remove pivot from bracket (6). 12
f. Remove bracket from extension tube (7).
g. Remove extension tube from exterior tube
grsnsr.3
bracket support.
h. Remove interior tube support bracket (8) from Step 3:
edger guide mount tube (9). Disassemble the power switch.
a. Remove the rear cover (13).
b. Remove the power switch (14).
5 6
4
7
13
8
2 14
9
1 3
blawkntrl.3
Step 2:
swtbx.2
Disassemble the grade sensor assembly.
a. Remove the front plate mounting screws (10). c. Replace the power switch (15) if needed.
b. Remove potentiometer mounting screws (11). d. Replace the circuit breakers (16) if needed.
11
10
10
16
11
15
grsnsr.1 swtbx.3
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Control Systems Highway Class Paver/Finishers
Step 4: ASSEMBLY/INSTALLATION
Disassemble the slope sensor assembly.
a. Remove front plate mounting screws (17). Install the Blaw-Kontrol II components by reversing
the disassembly and removal procedures.
ADJUSTMENT
Step 1:
Refer to Blaw-Kontrol II AGS 6.5 Operator's
17 Manual for adjustment procedures.
Step 2:
See “Electrical” section for troubleshooting
procedures and use of the “CH” mode.
spsnsr.1
20 19 18
spsnsr.3
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Highway Class Paver/Finishers Control Systems
APPENDIX D-1
VENDOR COMPONENT PUBLICATIONS LISTING
The following component publications are available from Blaw-Knox Technical Publications Department free of
charge to authorized Blaw-Knox dealers.
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