BOMAG PRO PAVER 813 Model GILCREST PROPAVER OPERATION, Instructions & Parts Manual

Printed in the United States of America. All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval systems, without permission in writing from the publisher. Gilcrest ProPaver, Inc. 306 East Second Street, Holden, Missouri 64040 Record the serial number for both the paver and engine in the space provided below. Your dealer needs this information to give you prompt, efficient service when you order parts or optional equipment. PAVER: MODEL NUMBER:_______________________ SERIAL NUMBER:__________________ ENGINE: MAKE:________________________ MODEL:________________________ SERIAL NUMBER:___________________________ OPTIONAL EQUIPMENT:_________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ DATE PURCHASED: ___________________________ DEALER NAME:_________________________________________________ CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

May, 2002 TABLE OF CONTENTS Introduction General Safety Instructions Locations Of Warning Decals Major Components Overview Operating Instructions Safety Suggestions for Operating Paver Loading and Unloading Procedure Drive Off Procedure Starting the Paver Steering and Speed Controls Conveyor and Auger Drive Controls Hydraulic Cylinder Controls Instruments Paving Depth and Width Crown/Valley Control Screed Heaters Screed Strike-Off Shoes Vibratory Screed Controls Cleaning (Washdown) System Tow Type Truck Hitch (Optional) Loading Asphalt from a Dump Truck Raising the Hopper Conveyor Bed 16 Foot Screed Extensions (Optional) Ditch Plates Maintenance / Service Procedures Safety Suggestions for Servicing the ProPaver Track Chain Adjustment Conveyor Adjustment Lubrication Points General Maintenance Wear Check Points Power Unit Maintenance ISUZU 4JB1 Engine Engine Troubleshooting 1 3 5 8 15 15 17 18 19 20 21 22 23 23 24 24 25 26 26 27 28 29 30 30 31 31 32 33 33 36 37 38 56

May, 2002 Parts Section ProPaver Parts Ordering Procedures 59 Yaw Beam Assembly w/ Bumper Rollers 60 Hydraulic Yaw Beam w/ Bumper Rollers old style 61 Hydraulic Yaw Beam w/ Bumper Rollers new style 62 Hopper Wing Installation 63 Wing Asphalt Barrier / Wing Handle 64 Front Asphalt Barrier 65 Screed Arm Assembly, Manual Depth Adjustment 66 Power Depth Adjustment 67 Adjustable Tow Point 68 Conveyor Bed Assembly 69 Conveyor Take-up Bearing Assembly 70 Conveyor Drive Assembly 71 Stir Auger Assembly 72 Track Fender 813 73 Track Drive Assembly 813 74-75 Hub Sprocket Mod # 6000567 76-77 Hub Sprocket Mod # 60001030 78-79 Hub Sprocket Mod # 60001292 80-81 Shuttle Manifold 82 Control Panel Console Assembly Left Hand 83 Hydro Control Lever Assembly Left Hand 84 Control Panel Console Assembly Right Hand 85 Hydro Control Lever Assembly Right Hand 86 Gate Cylinder Installation 87 Hopper Gate Installation 88 Fule Tank / LP Tank Installation, Spray Wand 89 Seat Installation 90 Screed Wear Plates 91 Main Screed Section 92-93 16 ft. Screed Extension 94-97 Screed Extension 18 in. Bolt-on 98 Screed Extension Bolt-on Gutter Attachment 99 13 ft. Screed Extension 100-101 16 ft. Screed Extension 2000 102-103 Joint Matching Shoe 2000 104 Screed Cylinder Anchor 105 Screed Extension 18 in. Bolt-on 2000 106 Screed Extension Bolt-on Gutter Attachment 2000 107 Power Unit Hopper Side Non_Turbo 108-109 Power Unit Operators Side Non-Turbo 110-111 Power Unit Hopper Side Turbo 112-113 Power Unit Operators Side Turbo 114-115 Power Unit Hopper Side Turbo w/Shroud 116-117 Power Unit Operators Side Turbo w/Shroud 118-119 Electro/Hydraulic Stack Valve Assembly 120 Stack Valve InletPlate 121 Solenoid Stack Valve 122-123

May, 2002 Screed Down Pressure Valve 124 Pressure Relief / Combiner Valve Assembly 125 Case Drain Manifold 126 Pause Assembly Manifold 127 Adjustable Flow Control 128 Ditch Plate Kit 129 Ditch Plate Kit 2000 130 Dith Plate Installation 131-134 Powerdepth Diagram 135 Model 813 with Shroud Option 136-137 Parts Ordering Information 138 813 Hydraulic Information Hydraulic Hose Routing 139 Gate Cylinders / Bed Lift Cylinder 140-141 Track Drive 142-143 Wing Cylinder / Screed Arm Clyinder 144-145 Lower Reservior Suction / Return 146-147 Upper Reservior 148-149 Goar / Comp Pump Pressure and Drain 150-151 Convayor Motors 152-153 Screed Extention Cylinde 154-155 Vibrator / Screed Extension Motors 16Ft 156-157 Screed Extension Motors 13Ft 158-159 Optional Equipment Power Screed Depth Controls 160-161 Hydraulic Yaw Beam 162-163 Common Replacement Parts 164 ProPaver Changes By Date & Serial Number 165 Hydraulic Schematic 168 813 Electreical Information Eletrical Diagram 169 Electrical Schematics 170 Warrany Statement Inside Back Cover NOTE: Product Changes and/or Additions will be published as Appendices.

Pro Paver by Gilcrest 1 This paver / finisher was carefully designed and manufactured to provide the utmost in dependable service. To obtain the best results and keep it operating efficiently, readand follow the instructions in the operator's manual. This safety alert symbol identifies important safety messages in this manual. When you see this symbol, be alert to the possibility of personal injury and carefully read the message that follows. This new machine has been factory tested, lubricated, and initial settings and adjustments carefully made. However, it is recommended that a thorough inspection of the entire machine be made prior to starting , to correct any problems which may have occurred during transit. The information contained in the Operator's Manual should enable experienced paving personnel to operate and maintain this unit. The sequence and detail of operating and servicing instructions are presented to assist an adequately trained equipment operator in performing paving and maintenance tasks. The specifications, descriptive information, operating, and servicing instructions contained in this manual were adequate and accurate at the time of approval for printing. Improvement of the product is a constant goal at Gilcrest Propaver, so we reserve the right to make changes at any time without notice and without incurring any obligation. Gilcrest Propaver is vitally interested in your satisfaction and we are anxious to help you with all of your maintenance and service needs. WARNING: Do not attempt to operate the Paving Machine before thoroughly reading, comprehending, and following the instructions in the operator's manual. Serious injury or death may occur!

Pro Paver by Gilcrest 2 General Safety Instructions One of the primary considerations in designing and manufacturing this Gilcrest Propaver was to make the machine and the operation of same as safe as possible. Shielding, simple adjustments and other safety features were built into the Paver wherever possible. All machinery should be operated and serviced only by responsible persons who have been properly instructed and delegated to do so. Read and thoroughly understand all instructions contained in this manual, the engine manual, and all optional equipment manuals before attempting to operate or service the paver. 1) Only the operators should be allowed on the operator's platform when the paver is in operation. 2) Clothing worn by all persons working close to the paver should be fairly tight and belted. Loose jackets, shirts or pants should never be worn because of the danger of getting caught in moving parts. 3) Be sure all shields and guards are in place and in good condition before starting the machine. 4) Always mount and dismount the paver from the rear, using the walkway, steps and handrails provided. Never dismount paver to the side, or forward. 5) Assure that all hands and feet are clear of moving parts before starting paver. 6) Make sure everyone is clear of the paver before starting so they cannot be struck by or caught in moving parts. 7) Never move the machine withe the hopper bed lifted in the "UP" or servicing position, this will make the paver heavy on the rear, and very hard to control. 8) Keep the operator's platform clean, Do not use it as a place to carry loose tools, lunch boxes, etc. 9) Refuel the paver only when the engine has been shut off. Do not permit sparks, open flames or smoking within 50 feet of paver when refueling. Never refuel paver with screed heaters lit and operating. 10) Never allow horseplay near the paver when it is in operation or being serviced. Safety is no Accident- Take time to be Safe!!

Pro Paver by Gilcrest 3 Escaping hydraulic fluid under pressure can have sufficient force to penetrate the skin, causing serious personal injury. Before disconnecting any hydraulic lines, be sure to relieve all pressure. Before applying pressure to a system , be sure all connections are tight and that all lines, tubes, and hoses are not damaged. Fluid escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks. 11) If injured by escaping fluid, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately. 12) Always be sure that all control switches are in the "OFF", "Pause", or "Neutral" position, hopper wings and screed are lowered and the engine is shut off before leaving the operator's station. 13) Never use the wash down system when the screed heaters are lit or operating. 14) Never clean, lubricate, or service the paver when it is running. 15) Do not open propane valves to the screed burners unless flame is present to light the burners. An accumulation of unburned gas could result in explosion. Do not allow smoking when lighting propane fired screed burners. 16) Do not allow smoking or the use of open flame when checking the electrolyte level in the battery. An explosion could result. If skin or eyes are exposed flush immediately with water and see a doctor. 17) Refill the radiator only when the engine is stopped or idling slowly. This paver has a pressurized cooling system. To avoid being scalded when radiator cap is removed, first turn cap to slightly to the stop which allows steam to escape through the overflow pipe. After all pressure is relieved, remove cap. 18) Never attempt to service or enter under the elevated hopper bed unless the safety prop is in place and secured. Serious Personal Injury Or Death Could Result! Accidents Dont't Just Happen - They are Caused! Take Time To Be Safe!!

Pro Paver by Gilcrest 4 Safety suggestions for persons working in the area of an operating paver 1) When working in the vicinity of the machine, stand in full view of the operator; but never in front of the machine when the machine is operating. Stay clear of hopper, side arms, and screed when machine is operating. Do not walk in front of the hopper or extended screed, or stand at the end of the screed if the hydraulic screed extensions are being used. 2) If necessary to remove spillage from the roadway, have theoperator stop the machine first. Working close to a moving machine is dangerous 3) Do not remove paving material from the hopper or auger trough while the paver is operating. The operator should be advised when adjustments are being made. 4) Do not attempt service or repairs you do not understand or cannot perform competently. 5) Never go between the tuck and the paver. 6) Do not attempt to clean , lubricate or service the paver while it is running. 7) If any safety related defects are discovered, inform the operator to shut the machine down and correct the defect. Safety Doesn't Cost- It Saves!! Take Time To Be Safe!!

Pro Paver by Gilcrest 5 LOCATIONS OF WARNING DECALS If any Safety/Warning Decal becomes illegible or torn, please call or write the following for free replacements: GILCREST PROPAVER, INC. PRODUCT SAFETY DEPARTMENT 306 EAST SECOND STREET HOLDEN, MO 64040 1-800-451-4808 ITEM DESCRIPTION 1 CAUTION Under Pressure Do ot Open While Hot (P# 0080014) 2 California Proposition 65 Warning Diesel engine exhaust and some of its constituents areknown to the state of California to cause cancer, birth defects, and other reproductive harm. (P# 0080008) 3 Warning! Do not attempt to operate this machine before thoroughly readingOperating Instruction Manual. Serious injury or death may result. (P/# 0080004) 4 Caution - Before raising screed, swing the seat away from all possible contact with the depth adjustment screw. Be sure that hands, feet, and legs of all personnel are clear of moving adjacent members of the machine, whenever raising or lowering the screed. (P/# 0080006) 5 Warning! Do not, under any circumstance, enter area under raised conveyor bed, unless onveyor bed prop is securely in place to prevent unintended closure. Serious injury or death may result! (P/# 0081309) 6 !!WARNING!! Stop engine and remove ignition key before makeing any adjustments replaceall protective covers before operatting machine. Serious injury may result if ignored NOTICE Remove cover and tighten taperlock bushing screws, to 15ft. lbs., After 1 ST 25 hours of operation and then check every 250 hours after. (P# 0081327) 7 Danger! Keep hands and feet away. (P/# 0080001) (Two per side/Four total) 8 Danger! Rotating augers. Keep hands out. (P/# 0080003) (One per side/two total) 9 Danger - Pinch Area. (P/# 0080000) (One per side/two total) Replacement Decals for Propaver 813 RT Part # Item Decal - Keep manual With Paver Decal - 813 RT Decal - Hyd Filter / Amp Decal - We Cover The World 7X9 Decal - 6 Bank Valve LH 813 1997 Decal - LH Control Panel 1997 Decal - Track Control Panel 1997 Decal - RH Control Panel 1997 Decal - 4 Bank Valve RH 813 1997 Decal - More / Less Handle 813 1997 Decal - Screed Arm 813 RT RH 1998 Decal - Screed Arm 813 RT LH 1998 Decal - ProPaver Wing RH 1998 Decal - ProPaver Wing LH 1998 Decal - ProPaver By Gilcrest 0080005 0081300 0081301 0081315 0081320 0081321 0081322 0081324 0081225 0081326 0081352 0081353 0081402 0081403 0100010

BOMAG PRO PAVER 813 Model GILCREST PROPAVER OPERATION, Instructions & Parts Manual

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